Professional Documents
Culture Documents
Shell Malaysia
Compressor Control System
TABLE OF CONTENTS
1. GENERAL INFORMATION -------------------------------------------------- 1-1
Introduction ----------------------------------------------------------------------------------------------------------- 1-1
Compressor Control System Description & Overview -------------------------------------------------------- 1-1
Table of Contents
Page ii
Shell Malaysia
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
Table of Contents
Page iii
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:
GENERAL INFORMATION
Page 1-1
Shell Malaysia
Compressor Control System
Page 2-1
Shell Malaysia
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.
OPERATOR GRAPHIC DISPLAYS
Page 2-2
Shell Malaysia
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.
Page 2-3
Shell Malaysia
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.
Page 2-4
Shell Malaysia
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.
Page 2-5
Shell Malaysia
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.
Page 2-6
Shell Malaysia
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.
Page 2-7
Shell Malaysia
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.
Page 2-8
Shell Malaysia
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.
Page 2-9
Shell Malaysia
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.
Page 2-10
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]
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]
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.