Professional Documents
Culture Documents
Edition 4.01
General Description
HydroCOM 4.0
2 ABBREVIATIONS .................................................................................................3
3 GENERAL FUNCTION..........................................................................................4
3.1 What is HydroCOM? ...............................................................................................................................4
4.8 Fast-TIM.................................................................................................................................................14
5 INSTALLATION EXAMPLES..............................................................................18
2 Abbreviations
The following abbreviations are used throughout this manual
This system saves compression power at part load, since the energy
consumption of a compressor is proportional to the quantity of gas
compressed per compression cycle.
The capacity closed loop control is done by the DCS / PLC or an optionally
supplied loop controller.
The following diagram shows the schematic layout of HydroCOM and the
optionally supplied Fast-TIMs and the on-line monitoring system,
HydroCOM-CCM:
Field
Feld
Feld Switchroom
Schaltraum
Schaltraum DCS
Warte
48 VDC EPS
TDC
IA
BUS
4...20 mA
Binäre Signale
HOERBIGER
HOERBIGER
HOERBIGER HOERBIGE
HOERBIGE
HOERBIGE
PoR
wer R R
TDC 5V
En abl e
Valve# Valv e# Valve# Ext.Sim.
P 15V
Code# Code# Code# Se nsor
hy
Error
Ld
S oM
U O
Scroll/ Scroll/ Scroll/
D -
Res et Reset Reset B
U 0/ /
S
SIM 1 SIM 2 SIM 3 GIM IPS
Überwachung
Monitoring
Überwachung
CIU
OIL
40
40
HU
Fast-TIM HSS HydroCOM-CCM
All suction valves are equipped with HydroCOM actuators. They perform the
actual control task – delaying the closing of the suction valves at part load.
Hydraulic unit (HU) and hydraulic piping supply the mechanical energy to the
actuators.
HydroCOM 4.0 features data acquisition of fast signals and can be upgraded
into a monitoring platform. The measurements can be read as analog
signals or via the digital Monitoring Interface (Modbus). If the on-line
compressor condition monitoring system HydroCOM-CCM is installed, the
CIU is the interface for the CCM-PC.
p
Dr
A
pD D
Energy savings at
50% part load
Cr
C
pS
B
V
Fig. 2.: The principle of reverse flow regulation
Check
Check
valve
valve
Solenoid
Solenoid
valve
valve
Hydraulic
Hydraulic
cylinder
cylinder
Hydraulic
Hydraulic
unit
unit
Unloader
Unloader
Suction
Suction
valve
valve
The suction valve sealing elements are controlled by the unloader. The
unloader is driven by the HydroCOM actuators. In the actuator a fast
switching solenoid is foreseen. Just before suction valve opening the
As shown in the diagram the indicated power for app. 50% load is only about
half of the power required for full load. Thus the principle of reverse flow
regulation saves energy compared to bypass control.
DCS
PLS / SPS
0 – 100 % 0 – 100 %
Rampe
Start Ramp
Skalierung
Scale Skalierung
Scale
1. Compressor Stage
2. Compressor Stage
St Ko St Ko
uf m uf m
Suction Pressure
Suction Pressure
e
1. pr e
2. pr
Sa es Sa es
ug so ug so
1. Stage
2. Stage
dr rst dr rst
uc uf uc uf
k 1.
e k 2.
e
4 – 20 mA 4 – 20 mA
Signal Signal
PT PT
Stufe
1. Stage Stufe
2. Stage
Japan: Ex de IIB + H2 T4
• HydroCOM Actuators
• Compressor Interface Unit (CIU)
• External Power Supply (EPS)
• Isolation Amplifier (IA)
• TDC-sensor
• Hydraulic Unit (HU)
• HydroCOM Service & Configuration Software (HSS)
• Transmitter Interface Modules (Fast-TIMs) and HydroCOM-CCM
The actuators comprise of the valve housing, the seal housing and the
electric housing.
Valve
Valve Housing
Housing
Oil
Oil inlet
inlet
Solenoid
Solenoid
Valve
Valve cartridge
cartridge
Soft
Soft touch
touch damper
damper
Oil
Oil outlet
outlet
Piston
Piston cartridge
cartridge
High
High pressure
pressure piston
piston
Seal
Seal Housing
Housing
Leakage
Leakage out
out Electric
Electric Housing
Housing
Flare
Flare connection
connection Connection
Connection boxbox
Wiper
Wiper rings
rings Printed
Printed circuits
circuits incl.
incl.
Guiding
Guiding rings
rings Microcontroller
Microcontroller and
and
Sealing
Sealing rings
rings Valve
Valve driver,
driver,
Temperature
Temperature sensor
sensor Fuses,
Fuses, Bus
Bus Interface
Interface
Unloader
Unloader Rod
Rod
In the valve housing the 3/2 way valve is actuated by the solenoid and the
retracting spring. Depending on the position of the 3/2 way valve the
actuator piston is either exposed to the pressure maintained by the hydraulic
unit or to atmospheric pressure (tank). The high pressure of the actuator
acts directly on the unloader rod. Up streams of the 3/2 way valve a check
valve is located. During the phase of reverse flow through the suction valve
the hydraulic oil is trapped by the check valve. Consequently the pressure in
the high pressure cylinder can exceed the pressure of the hydraulic unit.
The seal housing provides the sealing of the unloader rod. Sealing is
performed by a wiper element, several sealing elements and guiding rings.
Between the upper and lower sealing element a ring chamber with flare gas
connection is located.
A temperature sensor is located within this seal housing with the sensing
point very close to the suction valve cover. The suction valve cover
temperature is used for continuous monitoring of suction valves and flow
regulation. The measurements can be transferred via CIU analog outputs or
Modbus interface to the DCS/PLS or HydroCOM-CCM.
During operation some oil may gather at the bottom of the piston. The oil
leakage is tapped by a leakage oil connection into a collecting tank.
The actuator electronics are mounted within the flameproof electric housing
(EEx-d). The electronics control the solenoid, measure the valve nest
temperature and hydraulic pressure (option). Each Actuator is equipped with
a microprocessor to fulfill these tasks. This microprocessor solves drive,
monitoring, and communication functions. The electrical lines (48VDC and
HydroCOM field bas) are connected the EEx-e connection box.
4.5 TDC-sensor
The TDC-sensor synchronizes the HydroCOM system with compressor
speed and determines the position of the crankshaft. Each revolution the
TDC-sensor sends one reference impulse to the CIU. CIU and TDC-sensor
are electrically separated by the isolation amplifier IA.
The TDC-Sensor is a cylindrical, inductive proximity switch according to DIN
19234 (NAMUR).
The drawing below shows the basic design of the hydraulic unit.
Hydraulic oil is pumped via a gear pump into the system. The oil is
connected to the circuits of each stage via redundant high-pressure-filters
with check valves (visual blocking indication).
For each compressor stage one circuit is used. The maximum operating
pressure is maintained through a pressure control valve. Any overflowing oil
is cooled down in a cooler and is sent via a return filter to the tank.
By a built in thermostat the oil cooling circuit will be switched off at low
ambient temperatures to avoid too low hydraulic oil temperatures.
PT
Bypass for Pressure gauge
detensioning HU
Switch-over high
pressure double filter
Pollution display
3µm 3µm
Motor
Pressure relief valve
Thermostat °C
Airing filtre for tank
Pollution display
Filling filtre for tank
M Temperature transmitter
Return filter 10µm
Level switch
10µm TT LS
500µm
max
Oil level display
min
Oil tank Drain valve
Oil pump
• HydroCOM
• HydroCOM-CCM
• ROD-Position Analyzer (on-line rider ring wear monitoring)
4.8 Fast-TIM
Fast-TIMs (Fast-TIM transmitter interface module) enable decentralized data
acquisition and bus communication. Fast-TIMs are designed for connecting
fast signals (e.g. indicator pressure, rod drop) and slow signals (e.g. valve
nest temperature). Fast-TIMs contain power supply and barriers for
intrinsically safe transmitters and are mounted on or next to the compressor
frame, reduce field wiring and cut installation costs significantly.
Since the Fast-TIMs are installed like the actuators in the field its electronic
is mounted in flame-proof housings. The electric connection is identical to
the actuator. In addition to the actuator there is an additional connection box
for intrinsically safe transmitters:
Fast-TIM/8C: 8 channels:
All channels for 4-20mA transmitters (slow or fast signals)
Fast-TIM/6M 6 channels:
4 channels for 4-20mA transmitters.
2 channels for rod drop transmitters.
Fast-TIM/4R 4 channels:
All 4 channels for rod drop transmitters
The CIU makes the data available to the CCM-PC performing analysis and
monitoring. The industrial type CCM-PC can be installed in the HydroCOM
control cabinet. Data from your PLC/DCS are integrated via Modbus or
OPC.
Full network integration enables user access via network (LAN, WAN,
Internet) or modem with the HOERBIGER supplied Visu-Software.
Run-out:
Additionally the RPA works as on-line “dial indicator” to determine the
vertical run out during operation. A change in run-out indicates excessive
crosshead clearance, alignment problems and a loose connection between
piston and crosshead.
In addition to the CIU, EPS and TDC-sensor the rod-position probes have to
be installed. The probes are fixed to the pressure packing and are wired to
the Fast-TIM that is mounted locally at the compressor. The values for
stand-out and run-out are transmitted to PLC/DCS with the CIU analog
outputs (4..20mA) or Modbus.
Actuators
Hydraulic Unit