Ge Oil and Gas Al: Process Control and System Protection

GE OIL AND GAS AL
PROCESS CONTROL AND SYSTEM PROTECTION

Customer Southern Cooper Date 10/11/2017
Project Toquepala Order Number ZS1261157
Item:
Part Number 3017751 Unit Description SPS,19 2SR2500A 6STG 8213 2.5K*
Pump Model SR2500 Pump Stages 6 Pump OD 13" Skid Length 227.5"
Motor HP 1250 Motor Frame WPII-8213 Thrst Chbr XDTC Cooling BOL30
Starter Customer Sup Manufacturer GE Control 170ETH Size
Readings/Control
Component Parameter In/Out Type Control
Motor Space Heaters (8200-SH/221A...224A/321A...324A/421A...424A/521A...524A) O D N
Winding Temp(RTD) I A Y
Phase A-> (8200-TE/221C...224C/321C...324C/421C...424C/521C...524C)
Phase B-> (8200-TE/221E...224E/321E...324E/421E...424E/521E...524E)
Phase C-> (8200-TE/221G...224G/321G...324G/421G...424G/521G...524G)
Bearings Temperature (RTD) I A Y
DE-> (8200-TE/221A...224A/321A...324A/421A...424A/521A...524A)
NDE-> (8200-TE/221B...224B/321B...324B/421B...424B/521B...524B)
Bearings Vibrations (Accelerometer) I A Y
DE Ver.-> (8200-VT/221A...224A/321A...324A/421A...424A/521A...524A)
DE Hor. -> (8200-VT/221B...224B/321B...324B/421B...424B/521B...524B)
NDE Ver.-> (8200-VT/221C...224C/321C...324C/421C...424C/521C...524C)
NDE Hor. ->(8200-VT/221D...224D/321D...324D/421D...424D/521D...524D)
Currents (ABC) in Amps (read at VFD) I C N
Motor Voltage P-P (AB; AC or BC) in Volts (Read at VFD Output) I C N
Motor Frequency in Hz (read at VSD Output) I C N
Pump/Process Suction Press Value (8200-PT/221A...224A/321A...324A/421A...424A/521A...524A) I A Y
8200-PP Discharge Press Value (8200-PT/221B...224B/321B...324B/421B...424B/521B...524B) I A Y
(01/02/03/04) Vibration Thrust Cham(8200-VT/221E...224E/321E...324E/421E...424E/521E...524E) I A Y
(05/06/07/08) Temp Thrust Cham (8200-TT/221...224/321...324/421...424/521...524) I A Y
(09/10/11/12)
Flow Metter Flush Plan(8200-FT/221B...224B/321B...324B/421B...424B/521B...524B) I A Y
(13/14/15/16)
Cooler Oil Flow Thrust Cham (8200-FT/221A...224A/321A...324A/421A...424A/521A...524A) I A Y

8200-PP Space Heaters (8200-SH/221B...224B/321B...324B/421B...424B/521B...524B) O D N
(01/02/03/04-HU) Start Cooler I D Y
(05/06/07/08-HU)
(09/10/11/12-HU)
(13/14/15/16-HU)
Booster Pump Suction Pressure Value (transmitter) I A Y
(Not supplied)
VFD Line Voltage P-P (AB; AC & BC) in Volts I C Y

(Not supplied) Line Voltage Unbalance I C Y
Line Frequency in Hz I C N
Input Current (A; B & C) in Amps I C Y
DC Bus Current I C Y
Line Current Unbalance I C Y
A=Analog signal
Notes: D=Digital
C=Communication
GE OIL AND GAS AL
Item:
Process/Control
Process Control Comments
Unit Start / Stop
Start to run Routine
Page 1 of 3
Verification routine before
1
start the unit
YES 3rd consecutive NO

start?
Send Failure Alarm YES Motor Winding NO

RTD´s
OK?
Lock START
(Local and remote)
NO YES
Motor Winding ALARM ON
1 hour 1C
>= to 100°C? CHECK HIM
Delay
Start hour counting

Switch ON local 1 hour RTD ON
Sequence Step by step Delay
1B
NO 1
New Stop in the YES YES NO
next 4 hours? T=180
1A Horas
UNIT STOP
1A 1B
Lock START
(Local and remote) UNIT START UP START
1D
Switch ON
LOCK CODE
Corrective A
Maintenance
Plan
Switch OFF
LOCK CODE
1C
GE OIL AND GAS AL
Item:
Process/Control
Unit Start / Stop
Page 2 of 3 A
Could be either a manual start

Local Start Remote Start at pump location or a remote
start from a control room
Start Oil Cooler Motor Lubrication Start
180 sec
YES
Delay
Cooler NO Ensure TC Lubrication
Running?
YES Oil Press / Flow NO

Ensure Oil Cool Press/Flow
Normal?
Stop Oil Cooler Motor STOP
Start Booster P Motor Send Failure Alarm
5/6 sec 1
Delay YES
Booster P NO Ensure Suction Pressure
Running? in main pump
YES Suction
Press Main NO
Above 30 PSI
Pump
Normal?
Stop Booster P Motor STOP
Send Failure Alarm

Ensure TC
30/60 sec
Delay Lubrication and
1 Pressure in suction
pump
Start Main SPS Motor
B
GE OIL AND GAS AL
Item:
Process/Control
Unit Start / Stop
Page 3 of 3
B
During Operation
Control Process 1D Open loop rpm control
UNIT STOP STOP
Local Stop Remote Stop
Stop Main SPS Motor
5/10 sec
Delay
Stop Pump Booster

Motor
30/60 sec
Delay
Ensure TC Lubrication
Stop Oil Cooler Motor
Along Coast Time
Start Drive & Motor Avoid motor

Space Heaters Internal Condensation
End of Start/Stop
Routine
GE OIL AND GAS AL
Item:
Process/Control
During Operation
Main Motor UNIT RUNNING 2
Protection
YES Motor Winding NO

Temp Normal? Motor Winding RTDs
readings
2 Trip Failure Alarm
STOP UNIT
YES Motor Bearings NO

Temp Normal? Motor Bearings RTDs
2 readings
Trip Failure Alarm
STOP UNIT
VFD
Currents (Amps) OVERLOAD CONTROL
Current Under
Control YES NO VFD CTs A; B & C
Motor Nameplate
Amps? Any
2
Trip OL Alarm
STOP UNIT
UNDER LOAD CONTROL
YES Current Over NO VFD CTs A; B & C
UL Set Point?
Any
2
Trip UL Alarm
STOP UNIT
YES Amps NO
Unbalance CURRENT UNBALANCE
under 15%? VSD CTs A; B & C
2 Unbalance Calc.
Trip Current
B Unbalance Alarm
STOP UNIT
GE OIL AND GAS AL
Item:
Process/Control
During Operation
VFD B
Current
Control (Cont)
MOTOR CURRENT UNBAL

VSD Output VFD Out CTs A; B & C
NO YES
Current Calculated
Unbalance
2 Trip Motor Current
Unbalance Alarm
STOP UNIT
P-P Line Volts

YES UNDER VOLTAGE CONTROL
VFD NO
Under 3432V? VFD PTs A-B; A-C & B-C
Voltage
Any
Control
2
Trip UV Alarm
STOP UNIT
P-P Line Volts OVER VOLTAGE CONTROL

NO YES VFD PTs A-B; A-C & B-C
Over 4194V?
Any
2 Trip OV Alarm
STOP UNIT
Voltage VOLTAGE UNBALANCE

YES NO
Unbalance VFD PTs A-B; A-C & B-C
under 5%? Unbalance Calc.
2 Trip Voltage
Unbalance Alarm
STOP UNIT MOTOR VOLTAGE

VSD Output
Voltage Reading VFD Output Voltage Reading
C
Variable where
V/Hz = K (Constant)
2 No Control
GE OIL AND GAS AL
Item:
Process/Control
During Operation
VFD
Frequency
Control
LINE FREQUENCY
Line Frequency
Reading Only
Reading
Line Frequency at VFD In
MOTOR FREQUENCY
Motor Operating
Reading Only
Frequency Reading
Frequency at VFD Out
As per operating
frequency setting
D
GE OIL AND GAS AL
Item:
Process/Control
During Operation
Pumping Process D
Pressure
SUCTION PRESSURE
NO Suction YES
Pressure Transmitter
Pressure Opens Bellow Minimum
Tx low? Suction Pressure Set
2 Trip Low Suction Indicate LOW Pressure at
Pressure Alarm Pump Suction
STOP UNIT
DISCHARGE PRESSURE
NO Discharge Pressure Transmitter
YES
Pressure Opens Above Maximum
Tx high? Discharge Pressure Set
Indicate HIGH Pressure at
2 Trip High Suction
Pump Discharge
Pressure Alarm
STOP UNIT
Pump Suction SUCTION PRESSURE

Pressure Pressure Transmitter
Reading Only
Pump Discharge DISCHARGE PRESSURE

Pressure Pressure Transmitter
Reading Only
E
GE OIL AND GAS AL
Item:
Process/Control
During Operation
Pumping Process E
Vibration
T-Chamber COUPLING VIB

Motor Coupling
Mot-TC coupling Vibration Occur
NO YES
Vibration
Vibration
Vibration is open?
is open?
Tx High?
Open?
2 Trip
TripMtr
TC Coupling
Vibration
Vibration
Vibration Alarm
Alarm
STOP UNIT
THRUST CHAMBER TEMP

TC Temperature Transmitter
NO YES
Temperature Read Internal TC Temp Offset.
Over Limit?
2 Trip TC Temp.
Temperature high
STOP UNIT
Thrust Chamber
TC
NO YES Flow failure
Oil Flow
High/Low?
2 Trip Oil Flow XDTC

Lubrication Alarm
STOP UNIT
Flush Plan
Flush Plan
NO YES Flow failure
Water Flow to the seal
High/Low?
2 Trip for Flow

Flow Alarm
STOP UNIT

Ge Oil and Gas Al: Process Control and System Protection

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GE OIL AND GAS AL

PROCESS CONTROL AND SYSTEM PROTECTION

Cooler Oil Flow Thrust Cham (8200-FT/221A...224A/321A...324A/421A...424A/521A...524A) I A Y

VFD Line Voltage P-P (AB; AC & BC) in Volts I C Y

YES 3rd consecutive NO

Send Failure Alarm YES Motor Winding NO

Start hour counting

Could be either a manual start

Start Oil Cooler Motor Lubrication Start

YES Oil Press / Flow NO

Stop Oil Cooler Motor STOP

Start Booster P Motor Send Failure Alarm

Send Failure Alarm

Start Main SPS Motor

UNIT STOP STOP

Local Stop Remote Stop

Stop Main SPS Motor

Stop Pump Booster

Start Drive & Motor Avoid motor

YES Motor Winding NO

YES Motor Bearings NO

MOTOR CURRENT UNBAL

P-P Line Volts

P-P Line Volts OVER VOLTAGE CONTROL

Voltage VOLTAGE UNBALANCE

STOP UNIT MOTOR VOLTAGE

Pump Suction SUCTION PRESSURE

Pump Discharge DISCHARGE PRESSURE

T-Chamber COUPLING VIB

THRUST CHAMBER TEMP

2 Trip Oil Flow XDTC

2 Trip for Flow

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