AUTOMATION

OF RECIPROCATING GAS ENGINE COMPRESSOR PACKAGES USING

PROGRAMMABLE LOGIC CONTROLLERS
Copyright Material IEEE Paper No. PCIC-89-35

W.H. Goff, Member IEEE

ARC0 Oil and Gas Co. Dallas, Texas Abstract An approach taken to automate gas/engine The compressor skid mounted packages is described. approach includes design criteria with s cia1 considerations f relating to the application o Programmare Lo ic Controllers (PLCs). Using typical industry standard specikations along with I/O lists, sequence narratives, and logic diagrams the PLCs may be pro rammed to perform the desired operation. The added capatilities of the PLC enhance simulation. checkout and startup. Introduction Reciprocating engine/compressor packages have long f been a mainstay o the oil and gas production industry. Typical applications may be to increase oil production by a technique called gas lift or increase as production by com ressing gas to pipeline pressure recfucing backpressure gas wells. The remote location o this equipment f on normally means using self contained control systems to o erate the process equipment, engine and compressor. TEe control systems have been slow to chan e from the well established pneumatic ( as or air) controy systems. As automation expanded, t i e older pneumatic systems were partially replaced by relay panels and later by PLCs. a prescribed operation to purge, start, load, and shutdown the compressor and engine. Figure 1. is a simplified flow diagram for a typical two-stage reciprocating compressor package. The yard valves include the suction, loading (purge), blowdown, discharge, and recycle valves. Solenoid valves are connected to the compressor package PLC to open and close the valves. Limit switches are added to show the open and close positions o the valves. The compressor package PLC f f monitors the position o the valves for correct operation of the compressor process equipment. Pressure and level switches on the process scrubbers and fuel gas filters are inputs to the PLC to provide safety shutdowns and alarms. Local pneumatic control from a level controller dumps the scrubber liquids to the produced water system. Temperature switches are installed on the exchangers and compressor discharge. The process equipment switches and solenoid valves are the primary shutdown and sequence control for the f process automation o the compressor package. The engine and compressor mechanical control must be incorporated in the automation to verify proper mechanical equipment starting and running conditions. Typical inputs to the PLC for the engine/compressor control are ressure, level, and temperature switches. These are general6 established by the vendor and must protect the mechanical equipment. Lubrication, fuel, and cooling systems are monitored as discrete input switches to the PLC. In addition engine and turbocharger speed must be sensed to startup and operate the engine properly. Other sensors are used for monitoring inlet air, make-u water and lubrication tanks, cylinder temperatures, anfvibration. SDecial Considerations The design and installation requirements must reflect f the needs o the existing operations and facilities. One consideration may be to use separate PLCs for other process equipment or packages essential to the compression equipment. Other criteria may be important to the designer such as the following:

ge

f Most applications o PLCs to compressor packages have been to interface the pneumatic shutdown/control system to other automation based control systems. Sometimes PLCs have been used to add alarm or shutdown controls in addition to the existing pneumatic controls. Little information has been available on using PLCs to accomplish f the actual sequence control o the engine, compressor, and process.
Using PLCs to automate production facilities including The reliability and offshore platforms is increasing 1. reduction in complex wiring and tubing has resulted in f reduced downtime and faster repair. The expansion o automation has reduced the operating personnel requirements for many facilities. This pa er is based on experience gained by the installation o r three reciprocating engine/compressor f packages on Gulf o Mexico remote unmanned platforms. All three packages were installed in 1988 in anticipation of f reduced gas reservoir pressures. The successful operation o the packages supports continued development o automation f projects with PLCs. Desicln Criteria The engine compressor package usually includes process equipment such as scrubbers, filters, and exchangers. Special design is provided for purging the system with gas f before startup. For unmanned facilities the degree o purging is important to assure safe operation. Control equipment must be rovided to allow the equipment to shutdown proper? &ring a problem while runnin or starting up. The esign al ows for blowing the system iown to prevent dangerous buildup o natural gas pressure. The f f yard valves are those valves which control the flow o gas through the process and compression system. The yard valves become critical and must be designed for fail-safe operation. These valves are opened and closed according to

1.

The PLC typically needs special environmental considerations such as air conditionin The PLCs for each of the compressors instalyed were located in air conditioned control buildings. The PLC may need to be installed in a manner to allow it to be moved with the compressor to a different site. Inter-posing relays may be required to interface with starters or heater contactors. SCADA input or other electronic devices may re uire special inter-posing devices. The leaage current through some PLC output devices ma be reater than the turn-on current o the interrace 3evice. f Special training or hiring of skilled technicians may be required to maintain the equipment.
89-CH2777-1/89/0000~0181$01.OO 8 19891EEE

2.

3.
4.

5.
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6.

Operating requirements ma need to be established to avoid radio inteArence caused by hand held radio transceivers. A local panel may need to be provided for use f by maintenance personnel. The addition o a local panel for the compressor installations f offshore provided a limited degree o local monitoring along with manual startup at the compressor skid.

7.

pilots. The conversion to all electric/electronic end devices was a significant change. Problems occurred with the f application o level and pressure switches which had not been considered. The level switches were not designed for the characteristic bridle installations and the compressor skid vibration. The pressure switch dead bands played havoc with establishing proper setpoints. Once these problems were resolved, the switch o eration was reliable. Careful selection and application of tEese end devices will prevent such problems. Although PLCs have the flexibility to monitor many types of inputs, certain monitoring functions which could be included in PLCs may still best be served b f specialized control units. An example o tks=rG installation o a temperature scanner to monitor the en ine f cylinder and turbocharger tem eratures. Although the F&s could have been programme1 and analog inputs provided, the design team decided that the added program complexity and significant changes which may later be needed could f disrupt the development o the compressor control system. The desi n requires that process safety shutdowns required by sa&y standards for offshore latforms be included. Although two levels o safety siutdown are f f normally required, three levels o shutdown were included. Electronic shutdowns from process equipment sensors (i.e.,pressure switches, level switches, etc.) are considered the f first level o safety shutdown. Pressure relief safety valves f and rupture discs provide the 2nd and 3rd levels o mechanical safety shutdown backup.

Decisions on whether certain devices should be converted to electrical or electronic may need to be made f based on experience and the degree o automation required. A decision was made to use the manufacturer's pneumatic control for ramping the fuel gas valves, fuel air ratio system and ovemor on our compressor skids. The decision was f base1 on the most practical degree o conversion for the equipment available. Other pneumatichydraulic equi ment that was not converted to electrical or electronic &vices included the pneumatic PID controllers for the suction and recycle control valves which loaded the compressor. The conversion from pneumatic control devices to electric/electronic sensors is a normal result expected when converting to the PLC based system. Special attention needs to be given to device selection when makin such conversions. Significant problems were encounterer? in the f installation o the new compressors offshore because of incorrect a plication of certain electric/electronic sensors. Prior instalPations used only pneumatic to electric pressure

RECYCLE V A L V E

DISCHAR G E VALVE
3 - b

--

r-3

2 - STAGE COMPRESSOR

TO SALES

BLOWDOWN VALVE

SUCTION VALVE EXCHANGER

2 TO
H. P. RELIEF

LOADING VALVE

4
182 -

TO PRODUCED WATER

.
SCRUBBER ( T YP)

Figure 1. Typical 2-Stage Compressor Flow Diagram

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The degree of safety shutdown provided by the PLC is de endent on the electrical system reliability. The stem voiage was selected to be 24 volts DC. The availabxty of DC power supplies for PLCs increases the reliability by providing battery backup support during utility or power outage. Additional criteria used to control the remote f operation o the compressor were:

Unfortunately, this information is of little help in the f development o a new PLC based control system where the purchaser must use his own criteria as the basis for the PLC and control system. For reciprocating compressors API 11P includes a table to define the shutdown, indicating, control and remote f devices. Table 1 is typical o the format which may be modified to communicate the purchaser's requirements. Shutdown/alarm function class designations have been established for compressor packages with the following definitions: Class "A' - Shutdown functions which are always active. Class "A' shutdowns prevent starting or initiate a shutdown when the trip condition is sensed. Class " B - Shutdown functions which become active after a predetermined time delay. Class "B'logic prevents the shutdown from becoming active until a specific time delay after the engine starts to crank. Class "C" - Shutdown functions which become active once the initial setpoint is reached. Class "C" logic prevents the shutdown from becomi; active until the compressor is device clears the shutdown loaded. Once the Class becomes active. Class "C' logic is usually described as logic to "cock the shutdown once the device is initially cleared as the compressor is loaded.

1.

The engine was locked out from starting remotely after a shutdown was initiated from a shutdown device. Only three successive restarts were allowed after the compressor was shutdown remotely and a restart was required.
A

2.

3.

normal remote shutdown would begin a cooldown cycle for the compressor.

4.

For normal maintenance, a local/remote switch was provided at the compressor panel for local start-up.

SDecifications
A reciprocating gas engine compressor package specifics on package typically incorporates references to API-11P , and data sheets developed for previous packages.

8''

Table 1. Shutdown/ A l d Indicator Location List

FUNCTION

Item
NO.

IUnit/Service GAS ENGINE UNIT

I I I
X

Ilndicator ]Control IAlarn /Shutdown IClass

LOCATION

Crank Case Oil Level TAG#: LG-34 High Jacket Water Temperature

x2
UA-2

x2 UX-2

TAG#:TE-3047 10 Jacket Water Low Differential Pressure TAG#: PDCL-6001 11 Jacket Water Tank Low Level TAG#:LCL-7802

TAH-3047

X
PDAL-6001

x2 UA-2

x2 UX-2

X
LAL-7802

x 2 x 2
UA-2 UX-2

4. Grouped signal only.

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Input/Output Lists
An input/output list is critical for defining the PLC requirements. Each item of the list needs to be clearly described including the function. The input/output (I/O) list should be established by including the vendor's specific safety requirements needed to protect his equipment. The list is also taken from process flow and com ressor/engine utility diagrams that are normally produced E r process packages. The final list should include the following:

B. Energize "Ready to Crank

light in Remote control anel (output #123), "Ready to Crank' light in Local Cont!ol Panel (output #102) and "Ready to Crank signal to SCADA system (output #83).
"

1.

f Tag number or label o 1/0 device.

2.
3.

I/O device (i.e., pressure switch, level switch, speed switch, etc.)
10 device interface requirements (i.e., motor / starter, AC control, etc.)

C. If in "Auto" mode sequence will continue at ste D In the manual start mode the sequence wilfstop at this point. Start a 5 minute timer. If unit has not started within 5 minutes initiate a shutdown on "Sequence Failure" (Outputs #58,66, & 99). Push "crank push-button on local control panel to initiate crank. D. Open discharge valve (SDV-5010) by energizing solenoid SDY-5010 (output #118).

E. Confirm discharge valve (SDV-5010) is open limit switch ZCO-5010 (output #118). From the narrative, the I/O list and Table 1;the information to establish the PLC logic is determined. Logic Diagrams Logic diagrams can be an important aid that relates the desired engine and compressor operation to engineering, maintenance, and operating personnel. The use of logic diagrams normally leads to the most basic approach to programming which saves rungs or steps of programming and gives the programmer more freedom in his approach. The programmer may find additional methods for improving the program if he is freed from creating the fundamental logic.

Sequence Narrative Although the 1/0 lists to a large degree define the f functions o operation, the PLC programmer needs to understand significantly more about the com ressor package. A sequence narrative or description furnisEes a means to communicate the correct operation. A sequence narrative for a reciprocating compressor f provides initial information on the sequence o events f required for each ste o the operation. The narrative explains the sequence Eom pre-lubrication through cooldown and postlube cycles.

f A sample portion o a sequence narrative is:

5. Engine crank cvcle

A. When 30 second purge timer times out start crank cycle.

d -

Logic state which ' I its output turns

Logical AND

AND

f-

on when all A

Logical Latch

Logical OR Logic state which turns its output on when any incoming signal is positive

Logic state which latches to steady condition output when - "A" is applied. Output continues regardless of state of "A" until reset by signal at "R". If both signals exist simultaneously the circled signal overrides.

NOTE: Logical invert -{NOT

Logic state to change a positive signal to negative and vice versa

Logic is positive. Signal is on when condition occurs. All discrete input contacts are closed during normal operations. All output solenoids or signals are normally energized during normal operation.

Figure 2. And/Or/Not Logic Symbols

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Figure 3. Logical Latch Symbol

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SUCTION PRESSURE LOW

-+
-DR

COMPRESSOR SHUTDOWN

.COMPRESSOR
RESET

-3

DISCHARGE PRESSURE LOW

Figure 4. Typical Class C Logic

f The proliferation o logic diagrams, truth tables, sequence charts, flow charting along with different formats (i.e., NEMA, ISA, etc.) requires that lo ic symbology and format be established before the logic %velopment. The logic symbology used for our compressor packages is shown in Figures 2 and 3.

Proaramming
A systems house was selected to furnish and pr the compressor package PLC. Their programmer u s x ? logic diagrams to develop the program and used techniques from his experience to add additional capabilities to the initial logic defined in the rogram. For example, programming a "CLOSE' lamp to &sh was used to show a valve closing from the open position.

Figure 4 represents a logic diagram for a Class-C shutdown. Applying this logic to relay systems would have required a timer to prevent a relay race as the pressure switches cleared on rising pressure. Because the PLC lo ic f must scan each rung o ladder logic prior to the next, $e logic as shown will function properly.

Simulatioq Simulation is a very valuable tool for debugging the PLC program and verifying the desired operation. Indicator lights are test connected to the PLC to repre5ent outputs such as solenoids, motors, and interface signals. Toggle switches are used to represent switch devices. For analog devices trip settings may be established and preset with signal generators. The number and layout o the devices determines how f accurately the simulation board represents the equipment. A simulation board with graphics representing the process along with the compressor and engine utilities creates a more interactive setting for simulating the compressor package operation. Figure 5 is a block diagram depicting the correlation o the different types o logic used for the compressor f f packages. Logic was first developed for process shutdowns and alarms by class (Class A, B, or C). As illustrated in f Figure 5, the operation o the yard valve solenoids and limit switches was created to correspond to the shutdown logic. For example, the suction valve could not be opened after a shutdown until a compressor reset occurred. The mechanical shutdowns were added and checked against the yard valve

The remaining program logic included the alarms, sequence failure logic, grouping of alarms for indication, and general administrative tasks. Care must be taken in the logic development when considerin shutdowns from and to existing shutdown systems o t t h e facility. When considered separately the logic can easily establish a continuous loop such that a shutdown in one system interlocks a shutdown in the other preventing f reset o either system. Both systems must be considered during the early stages of logic development. The most demanding logic devised was the cool-down f cycle. Each step o the logic had to be studied to prove the f equipment operating requirements for each action o the compressor cool-down. The cool-down cycle logic could not effect the normal startup and running logic. By looking at f each step o the sequence logic the cool-down cycle was integrated into the total system logic.

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L A
L

PROCESS AND MECHANICAL SHUTDOWN - LOGIC - . - [CLASS A. tl. C.]

.-.

^^

YARD V A L V E LOGIC (SOLENOIDS AND L I M I T SWITCHES)

\\

h//

SEQUENCE LOGIC (INCLUDING COOLDOWN)

ALARM AND MISC

Figure 5. Correlation o Different Logic f solenoids. The sequence logic was then developed to correspond to the shutdown and yard valve logic. Many iterations were required to verify the correct logic at each step o the sequence. The final sequence logic consisted of f the following drawings: 1. 2. 3. 4. Start thru Begin Prelube Prelube thru Begin Purge Purge thru Engine Ignition Engine Ignition thru Compressor Loaded diagrams become the predominant method for trouble shooting. Problems can be analyzed faster because the ladder programs can be printed with cross-reference documentation. "Search functions provide quick access to input and output locations in the ladder diagrams on the CRT displays.

An actual run test o the engine and compressor then f completes the debugging and verifies the sequencing f operation o the equipment. The run test of the engine may actually be performed before all the compressor package f construction is complete. One feature o most PLCs is to "force" inputs and outputs to different states. Another feature f allows for rapid changing o timer settings. These features mean the test can be carried out faster and without all the process inputs and outputs. Checkout and Startup

f The CRT also allows display o information during start-up for quick analysis of problems. Displaying the various timers used for sequencing the starting and shutting f down o the compressor package is another help to the start up team. As the equipment is started, the sequence status may be monitored. This information helps determine which equipment is operating correctiy or whether the system is f functioning properly. Because knowledge o the key points o the startup sequence can be valuable for maintenance f problem solving, sequence indicating lights were installed at the local compressor panel. Each light would show a certain f part o the start up sequence was completed. When all lights were lit the compressor was loaded and the lights were reset.
Observations Many other steps were taken in the automation development which were found to be impractical. For example, sequence ladder programming appeared to be a practical approach to reduce the logic development. Several different attempts were made to develop sequence function

f Checkout and startu o the engine/compressor was also simplified the use oPPLCS. During the checkout the outputs can be ' forced' to operate solenoids and outputs for field checks. Documentation available from the PLC printout cross references the signals. After startup the ladder

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charts. Too many variables at each level o the sequence f made that method impractical.

f During the checkout and startup o the first compressor/package several programming changes were f made to debug or enhance the operation o the unit. The original logic diagrams were then revised from the ladder f f diagram printout o the first unit for development o the other two packages.
Future development may be directed towards eliminating the pneumatic controllers by using electronic PID loops in the PLCs. Various manufacturer engine fuel su ply control systems may be desi ned into the PLCs by worEing with the engine vendors. dectronic governors are already available for engine control systems. As emission control requirements become more stringent more complex control schemes can be implemented using PLCs. Conclusion An approach taken to automate skid mounted reciprocating as compressor packa es has been presented using PLCs. %he automation inclujed start/stop and cooldown sequencing for remote unattended operation. The application as described sets the stage for future development such as load and recycle control. References

11 1

J. Thibodeaux, PLCs used for offshore

production-platform control; Oil and Gas Journal, July, 1988, PP 38-43.

12)

American Petroleum Institute (API) Specification 11P, API SDecification for Packaaed Reciprocatina Comixessors for Oil pnd Gas Production Services, June, 1989.

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