HydroCOM High energy savings and excellent controllability
For efficient capacity control Many capacity control systems waste energy, are slow and inaccurate. HydroCOM, however, achieves best results and pays for itself within a short period of time. It saves money due to excellent controllability and by significantly improving performance.
Some questions you should ask yourself
Economical aspects
Automation requirements
about your existing control system:
Does my control system waste energy like
Can my control system be fully integrated
a bypass valve?
into the DCS to allow remote control unlike pockets and manual operation?
Process issues
Does it provide any kind of self-diagnosis
Does my control system react quickly
functions?
enough and does it precisely control all required pressure levels, flow rates or
Environmental restrictions
other parameters unlike step control or
Does my system help to fulfil stringent
bypass valves?
environmental conditions unlike control-flares?
Control range Does my control system have any limitations with respect to molecular weight, suction pressure, temperature, minimum load, etc. as with speed control, pockets, step control etc.?
A wise investment HydroCOM is the smartest, most efficient, stepless, highly dynamic and fully automated control system.
What makes HydroCOM the perfect
Highest energy savings
Fully automated system
answer to your compressor control
HydroCOM follows an intelligent concept:
HydroCOM interfaces to a DCS or
system problems?
just the required amount of gas needed is
a loop controller.
being compressed.
Monitoring Stepless control range
Monitor and protect your compressor with
HydroCOM uses hydraulic actuation to
RecipCOM, our machinery protection and
use the full control range. HydroCOM
online monitoring system. RecipCOM
is independent of process variations
is certified according to IEC 61508 /
such as suction pressure, molecular
61511, API 670 and ANSI / ISA-84.
weight changes, temperatures, and other condtions.
Proven success HydroCOM is used in a variety of
Highest control dynamics
applications. Basically every reciprocating
HydroCOM is very fast and precise due to
compressor installation can be equipped
the quick response of the solenoid valve
with HydroCOM.
inside the actuator:
within 3 crank-shaft revolutions
load changes from 10 to 100% are possible.
Smart actuators are at the heart of HydroCOM
The basic principle of HydroCOM: Normally gas is being compressed during the compression stroke. With HydroCOM the suction valve is kept open by the unloader so a certain amount of gas is pushed back into the suction chamber. Then, at precisely defined point of time, the unloader is released and the
PD
A
D r,50 D Energy Savings at 50% partial load
e r u s s e r P
C r,50
suction valve closes. Therefore only the gas remaining in the cylinder is being compressed.
PS
C
B Volume
n Electric housing
oil-section of the valve housing and the
Microprocessors inside the electric
gas-section of the compressor.
housings handle the fast and precise actuator timing. When installing the actuator only power supply and bus cables have to be electrically connected.
o Valve housing The valve housing is the “hydraulic heart” of the HydroCOM actuator. Oil pressure
A temperature sensor measures continuously the valve cover temperature and makes this value available for indication in the process control system. This temperature is used to monitor the condition of the suction valve.
(connection on top) is applied to the
q HydroCOM unloader
hydraulic piston to push the unloader
The motion of the HydroCOM unloader
down when needed. The solenoid valve
is controlled by the hydraulic pressure
(similar to those in common rail diesel
applied in the valve housing.
injection systems) is the fast switching element giving the HydroCOM its high
r Suction valve
dynamics.
The HOERBIGER plate or ring type
p Seal housing The seal housing fits directly to the suction valve cover. It separates the
suction valve with non-metallic sealing elements ensures long life time and best efficiency.
2
1
3
4
5
HydroCOM integrates seamlessly
Modular system design HydroCOM’s modular design makes integration straight forward for both existing and new compressor installations. Process control tasks are implemented in a DCS or a loop controller. In a control panel the HydroCOM compressor interface unit (CIU) carries out data exchange between the DCS and HydroCOM.
Field
Switchroom
DCS / PLC
1 99 4
TDC 4-20 mA binary signal or Modbus
IA
BUS
CIU
OIL
CompressorConditionReport UnitName: Unit Name: Location: Location:
RTC21000-C RTC21000-C FLL FLL
Model: Model: UnitMfr: Unit Mfr:
TCV10 TCV10 DRE ES SS SEE RR RR AA NN DD
Date: 4/28/19948:18:32AM Date: SerialNo.: Serial
L ao d daS t Set:pep: 33 Percent Load:86.4 % UNITCOSTS Fuel Cost: BrakePowerfromtheload: Cost of Each BHP:
HSS
1673.37 $/day 3654.50 bhp 0.46 $/bhp-day
ENGINECOSTS Actual Fuel Consumption: Predicted Fuel Consumption: Deviation From Predicted: Cost of Deviation:
Percent of Fuel Cost 8675.17 BTU/BHP-hr 7434.80 BTU/BHP-hr 7434. 80 1240.36 BTU/BHP-hr 239.26 $/day 7282.35 $/month 87388.25 $/year
Total Losses Valve and Passage Losses:397.38 bhp Pulsation Losses: 153.18 bhp Gas Recirculation Losses: 0.78 mmscfd Total CompressorCost:
Estimated Cost ofLosses Percent of Fuel Cost 172.86 $/day 10.3% 10.3 66.63 $/day 4 . 0 % 5.97 5.97 $/day 0 . 4 % 245.46 $/day 7 4 7 1 2. 3 $ / m o h nt 89655.86 $/year
TOTAL DEVIATIONFROM PREDICTED
Hydraulic Unit
14.3%
COMPRESSOR COSTOFLOSSES
484.72 $/day 14753.67 $/month 177044.11 $/year
14.7%
Percent of Fuel Cost 29.0%
1 9 9 5
1 9 9 6
1 9 9 7
1 9 9 8
19 4 9
1 9 9 5
1 99 6
1 9 9 7
1 9 9 8
HydroCOM’s many success stories Many users worldwide take advantage of the outstanding performance of HydroCOM.
Nearly 600 HydroCOM installations are achieving significant advantages over other systems. HydroCOM installations are found in many industrial applications including:
Chemical plants
Refineries
Gas transport and storages
Gas turbine plants
Chemical
Gas turbine plant
Refining
Natural gas
HydroCOM´s leading edge technology, optimal integration and excellent maintenance features have proven to be the ideal choice for customized process control systems. Not only does HOERBIGER lead the way in compressor controls, it also provide local support from the largest service network in the world.
Refining
The benefits of HydroCOM at a glance
Maximum energy savings
Stepless control for excellent
controllability
Broad control range for process
Suction valve temperature
No additional space required
monitoring on-board.
High standardisation of parts /
Full integration into plant control
systems for high reliability and
system
cost effectiveness on spares
flexibility and easy start/shutdown
Fully automatic for easy operation
Fast and precise: ideal for stable
Easy and quick upgrade /
monitoring including pV, rider ring
integration, fits on most
wear and vibration monitoring
dynamic control
compressors HydroCOM Specifications Control Range
10 - 100% *
Max. suction pressure
160 bar / 2320 psi
Max. suction valve temperature
120° C / 220° F
Max. compressor speed
1200 rpm
Corrosive Environments?
yes
Non-lubricated service?
yes
Suction valve
non-metallic plate or ring
Max. number of actuators
48
Ex certifications
EU (ATEX), US (FM), Canada (CSA), Japan
* Control range depends on the application
www.hoerbiger.com
The HOERBIGER Group HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG, Zug / Switzerland. HOERBIGER is active throughout the world as a leading player i n the fields of compression technology, automation technology and drive technology. In 2008 , its 6,300 employees achieved sales of around 1 billion Euro. The focal points of its business activities include key components and services for compressors, engines and turbomachines, hydraulic systems and piezo technology for vehicles and machine tools, as well as components and systems for shift and clutch operations in vehicle drive trains of all kinds. Through innovations in attractive technological niche markets, the HOERBIGER Group sets standards and delivers cutting-edge solutions for the benefit of its customers.
Optional upgrade to online
Proven at nearly 600 installations
