Compressor

Automated compressor control system

In February 2023, we received a request to create an automated control system for a three-stage block compressor, including the creation of working documentation in accordance with the RD 50-34.698-9 standard. 


 
The appearance of the block compressor. It is supplied as a complete product and provides the necessary composition of functions designed to ensure safe operation of the product.

The terms of reference provided that:
1. The compressor delivery package must include all automation equipment that ensures operation and emergency protection of the compressor:
- primary converters (sensors) with analog input signals 4-20 mA, HART protocol; two-wire circuit, must be equipped with stainless steel valve blocks; powered by a control system
- fittings and selected devices with fittings for installing devices on the compressor;
- connection boxes, cables from peripherals to connection boxes and from boxes to control cabinets;
- a control system (controller, control panel) with the transmission of signals (operation, compressor shutdown, controller malfunction, etc.) to the general control system of the complex for the production of industrial alcohols (DCS) via digital communication channels, as well as the ability to turn off the installation in the event of an accident;
2. The contacts of the position sensors of the actuators are assumed to be normally closed (NC), the contacts and solenoid valves (24 V DC power supply) are "under current" under normal operating conditions. When the limit (emergency) values are reached, the contacts are opened and the solenoid valves are de-energized;
3. All primary converters, except temperature sensors, are equipped with built-in indicators;
4. The degree of protection of the shell of devices and controllers is not less than IP65;
5. The material of the pulse tubes is stainless steel;
6. Field instrumentation must be entered in the State Register of Measuring Instruments of the Russian Federation, have a certificate of primary verification on the territory of the Russian Federation or an agreement on recognition of the results of primary verification between the manufacturer and the State Standard, certificates / declarations.
7. OWEN control controller with the ability to receive and process HART signals from installed sensors, Modbus RTU protocol.
8. The application software should provide the possibility of remote debugging of the control system and protection of the three-stage compressor. The system was supposed to be able to receive information from the instruments via two independent channels. Using a unified 4-20mA signal and using the HART protocol. 

For the latter, solutions using multiplexers from Promavtomatika were applied.


 
The final appearance of the automation cabinet. The cabinet is based on a touch controller from OWEN SPK107.


 
The process of assembling the cabinet. Testing of all indication and control circuits prior to installation 
equipment in the container.



The compressor is in a metal container.


 
OWEN Power Supplies


 
OWEN modules work in conjunction with multiplexers from Promavtomatika (HART).


 
Block diagram

A separate requirement on the part of the Customer was the preparation of documentation in accordance with the RD 50-34.698-9 standard. The requirements for the composition of this documentation were prepared and agreed upon and the list was approved. I will publish the composition below:

B1 List of input and output signals
C4,C5 Electrical connection diagram
C6 Cable Magazine
C13 Table of settings and locks
C4 Modbus Address Map
C1 Description of the CCC
PB Description of algorithms
I3 Operator's Manual
B4 Specification
In the assembly drawing
C10 Electrical schematic diagram
E3 Single-line electrical circuit
RE Operation Manual
PS Passport
 

The list of input and output signals is the fundamental document of the entire project, which defines the composition of the project signals.


 
External wiring diagram


 
External connection diagram

 Cable Magazine


 Table of settings and locks

 
Modbus Address Map

 
Description of the CCC complex

 
Description of algorithms

 
Operator's Manual

Specification

 
Assembly drawing


 
Schematic electrical diagram



One-line scheme


 
Passport


Video frames of the system

 
Main video frame



Control video frame


 
A video frame of messages about violations that occur


 
A video frame of calibration and correlation of analog channels of the system and signals received using the digital HART protocol


 
Video frame of control of threshold limits of thresholds of violation of devices

 

A video frame for the possibility of replacing the current value with a simulated value


 
Video frame of signs that the installation is ready for launch

height="499" title="Video frame of digital inputs">
 
A video frame of the state of discrete input signals


 
A video frame of the state of discrete output signals


 
Video frame of the running time counters of nodes in operating hours

#Saukompressor, #OWEN, #PROMAUTOMATIKA, #MUX8