HydroCOM

13th National Award for Excellence in Energy Management 2012:

22 - 23 August 2012, HICC, Hyderabad
HOERBIGER India Pvt Ltd
Hoerbiger India Pvt Limited was incorporated on 1993 and is fully
owned subsidiary of Compression Technology a division of Hoerbiger
Group. The Company have Regional Offices in Delhi, Vadodara,
Chennai, Kolkata, Guwahati and Vishakapatnam.
PRODUCTS OF HOERBIGER INDIA
- Compressor valves for various gases / applications
- HydroCOM (Stepless Capacity Control System) & Continuous
Compressor Monitoring
- Wear Components -Cylinder Rings, Piston & Piston Rod , etc
- Screw Compressor Components
- Reed Valve for semi-hermetic, hermetic and air brake applications.
- Compressor Components Services & Snap Shot Monitoring.
- Altronics Engine Controls, Ignition Systems, GTI Bi-fuel systems etc

HydroCOM Stepless Capacity Control System 2

HydroCOM System - Features and benefits

Automatic capacity control system for reciprocating compressor

Fast and precise (much faster than a recycle valves)

ƒ Ideal for processes requiring stable dynamic control
ƒ Rapid response to changing demands (e.g. caused by problems
with up-/downstreams equipment or consumers)

High energy savings for quick amortisation

ƒ Only the required gas flow is compressed (no recycling)
ƒ Reduced tax for CO2 emissions

HydroCOM Stepless Capacity Control System 3

HydroCOM Offers Outstanding Merits

HydroCOM Stepless Capacity Control System 4

 Working principle

During the compression stroke, an unloader holds the suction valve open to reduce the suction gas
volume to the desired amount. HydroCOM releases the unloader at the desired capacity to close
the suction valve so that only the gas remaining in the cylinder is compressed. This is also called
reverse flow principal as excess gas goes back to suction.
HydroCOM Stepless Capacity Control System 5
Only required gas flow compressed
Energy consumption at 100%
capacity with recycle valve
control

Energy consumption at 50%

capacity with HydroCOM

Area enclosed by pV graph is

equivalent to the energy
consumed

HydroCOM Stepless Capacity Control System 6

High energy savings - Example
Typical application: Waste of energy:
800kW compressor
With 30% recycle valve control :
70% average load
Energy costs INR 7.00 per kWh 800 x 0.3 = 240 KW
Losses per year: 240 KWh * 8000 hrs
= 1,920,000 KW

100%
70% Recycle Gas is waste of money:
1920000 KW * Rs. 7 = Rs 13,440,000
30% per year
Energy saving using HydroCOM
system is INR 13.4 million

HydroCOM Stepless Capacity Control System 7

HydroCOM Key-components

Compressor
HydroCOM Hydraulic
Interface
Actuator Unit
Unit (CIU)

HydroCOM Stepless Capacity Control System 8

Components of HydroCOM – Actuator

HydroCOM Stepless Capacity Control System 9

Components of HydroCOM - Actuator

Actuator

Unloader

Suction valve

HydroCOM Stepless Capacity Control System 10

Components of HydroCOM - CIU

ƒ Interface between PLC/DCS

and actuators
ƒ Transfers load signal from
loop controller into opening/
closing commands for
actuators.
ƒ Hardwired I/Os and Modbus
Interface for data exchange to
PLC/DCS
ƒ Data display, service and
configuration with HydroCOM
Service Software (HSS)

HydroCOM Stepless Capacity Control System 11

Components of HydroCOM – Hydraulic unit

Pressure
transmitter

Oil/air cooler

Ex-proof motor Duplex filter

Temperature
transmitter

Level switch
(fork type)

Tank 63/120l

Shown: Hydraulic unit with 120l tank

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HydroCOM System layout

HydroCOM Stepless Capacity Control System 13

HydroCOM Components Installed on Compressor

HydroCOM Stepless Capacity Control System 14

HydroCOM Application range
Control range (0..) 10*…100%

Max. suction pressure 160bar

Max. suction temperature 120°C

Max. compressor speed 1200 rpm

Non-lube, corrosive gases yes

Suction valve sealing element ring, plate

Gases All, except O2 + acethylen

Ex-certification ATEX, Japan ExII 2G EEx de IIB + H2 T4

Ex-certification Canada (CSA) Class I, Div.1, Gr. A, B, C, D

Class I, Div.1, Gr. B, C, D, T4
Ex-certification US (FM)
AEx d,e IIB + H2 T4

HydroCOM Stepless Capacity Control System 15

Energy Savings in various Projects

Sr. Customer Plant Equipment Cost in INR Fuel Savings MT/

Lacs Year
1 IOCL Gujarat HCU 324 2000
2 IOCL Mathura DHDT 262 1000
3 IOCL Guwahati HDT 85 515
4 IOCL Barauni DHDT 225 2000

HydroCOM Stepless Capacity Control System 16

Energy Savings in various Projects

Sr. Customer Plant Equipment Cost in Fuel Savings MT/ Year

INR Lacs
1 IOCL Gujarat HCU 324 2000
2 IOCL Mathura DHDT 262 1000
3 IOCL Guwahati HDT 85 515
4 IOCL Barauni DHDT 225 2000

HydroCOM Stepless Capacity Control System 17

HydroCOM Project List
Compressor Compressor Motor Year of
Sr. Customer Plant Model Qty
Make Tag No Rating Commissioning
Numaligardh Refinery Ltd, 04-KA-003A (
1 HCU Nuovo-Pignone 4HF/3 3.3 MW 1 May-06
Numaligarh MUG)
Indian Oil Corp Ltd,
2 OHCU Nuovo-Pignone 4HF/3 07-K-03C (MUG) 3.2 MW 1 Apr-07
Mathura
3 IOCL Haldia DHDS NP 2HF/1 25-K-01A 2.8 MW 1 Mar-08
4 IOCL Haldia DHDS NP 2HF/1 25-K-01B 2.8 MW 1 July-08
Indian Oil Corp Ltd,
5 HTU Nuovo-Pignone 2HE/2 49-K-03B (MUG) 1.0 MW 1 Feb-09
Guwahati
6 BPCL Mahul, Mumbai HCU Kobe KR60/6 132-K-203B 4.2 MW 1 Apr-09
Chennai Petroleum Corp 207-MK-2C
7 HCU Thomassen C45.5 4.2 MW 1 May-09
Ltd Chennai (MUG)
Indian Oil Corp Ltd, 301-K-01A
8 DHDT Mitsui C454 4.2 MW 1 Jun-09
Mathura (MUG)
Indian Oil Corp Ltd,
9 DHDT Thomassen C454 702-K-02B 5.2 MW 1 Jul-09
Barauni
Indian Oil Corp Ltd,
10 CRU BPCL 2HD/1 03-KA-02A 0.8 MW 1 Aug-09
Barauni
Indian Oil Corporation Ltd,
11 HCU NP 3HF/3 06-KA-04A 2.8 MW 1 Nov-10
Gujarat, Vadodara
Dresser-Rand India,
14 HHE-
12 Ahemdabad (IOCL, VGO Dresser-Rand 2093-KA-02 A/B 4.8 MW 2 Nov-10
VL
Gujarat Refinery)

13 BPCL CPCL Chennai DHDT BPCL 4HF/2 211-K1A/B 2.5 MW 2 Apr-11

Bharat Petrolium
14 Corporation, Kochi DHDS NP 2HE/1 DDC-1B 1.5 MW 1 May-11
Refinery, Ambalmugal

15 HPCL Vizag DHDT NP 2HE/1 60K-01-A/B 1.1 MW 2 Aug-12

HydroCOM Stepless Capacity Control System 18

HydroCOM Project List
Compressor Compressor Motor Year of
Sr. Customer Plant Model Qty Remarks
Make Tag No Rating Commissioning
Thomassen
OE Fitted.
Compression Systems MC-RHZ-353-
16 JERP Thomassen C856 13 MW 3 Jan-09 Comm by
( Reliance Industries C01 A/B/C
HVW
Ltd, Jamnagar)

OE Fitted.
Neuman & Esser (BPCL
17 VGO N&E 3SVL500 VH-C-02 A/B 6.0 MW 2 Jan-11 Comm by
Cochin Refinery)
HVW
Neuman & Esser (HPCL OE Fitted.
18 (HPCL Bhatinda - N&E 2SZL500 507-K-002A-B - 2 Jan-12 Comm by
Refinery) HIPL
Neuman & Esser (HPCL OEM -
19 (HPCL Bhatinda - N&E 2SZL500 509-K-002 A/B - 2 Mar-12 Greenfeild
Refinery) Project

HydroCOM Stepless Capacity Control System 19

HydroCOM - Key Features
Only the required gas flow is compressed (no recycling)

Automatic capacity control system for reciprocating compressor

Saves energy and improves controllability

Ideal for processes requiring stable dynamic control

Rapid response to changing demands

Around 900 Installations Worldwide.

In India, 48 Sold & 25 Running. Other will be commissioned in 2012-13

HydroCOM Stepless Capacity Control System 20

HydroCOM - Key Features
Reduced tax for CO2 emissions

HydroCOM Stepless Capacity Control System 21