Descriptive Control Philosophy

Biogas Compression Package ZI-3765 (VG10828)

Customer: LOTTE CHEMICAL PAKISTAN LTD
Model: BVG90 (CH) / BVG90-6.0MG-INV (WSS-SF-IW-GOH-CM-BY2-PL-MB-LM) Ex

1. Index
2. Introduction ............................................................................................................................................... 2
2.1- Reference documentation ................................................................................................................. 2
2.2- General Information .......................................................................................................................... 2
3. System Operation Description................................................................................................................... 2
3.1- Gas Circuit .......................................................................................................................................... 2
3.2- Oil Circuit ........................................................................................................................................... 3
3.3- Suction Pressure Control ................................................................................................................... 4
3.4- Suction Condensate Drain System..................................................................................................... 5
3.5- Supply Air System .............................................................................................................................. 5
3.6- Ambient Air Recirculation.................................................................................................................. 5
3.7- Chiller and chilled water pumping Unit ............................................................................................. 5
4. Operational prerequisites.......................................................................................................................... 6
4.1- Manual checks ................................................................................................................................... 6
5. Automatic Actions at Power Up ................................................................................................................ 6
6. Automatic Actions at Start Up ................................................................................................................... 6
7. Automatic Actions at Stop ......................................................................................................................... 7
8. Trip and Emergency Shutdown ................................................................................................................. 7
9. Control modes ........................................................................................................................................... 8
9.1- Local Mode ........................................................................................................................................ 8
9.2- Remote Mode .................................................................................................................................... 9
10. Signals for customer .............................................................................................................................. 9
11. Safety Devices ........................................................................................................................................ 9

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2. Introduction
This document describes the control philosophy of the biogas compression package ZI-3765 that is equipped
with a Termomeccanica screw block, intended to deliver a biogas flow increasing its pressure.

This package consists mainly of a screw compressor with its oil lubrication system, driven by main electric
motor, complete with suction heat exchanger and filter, discharge oil separator, heat exchangers and filters,
equipped with chiller for cooling suction heat exchanger and with pumping unit to pump chilled water, along
with electrical panel (MCC) and control panel (UCP).

2.1- Reference documentation

- GA: ADI90280
- P&ID: ADI10690
- WD: ADI10691

Inst: CPU Micrologix Series1400

2.2- General Information
The electrical panel designed for this system has a power supply of three phases (400V 50Hz + PE).

Compressor is controlled by a PLC (Allen Bradley Compact Logix) and HMI (Allen Bradley)

There is a communication interface for Customer through Modbus RTU

3. System Operation Description Inst: Please share relevant HMI

The compressor package consists of: screenshots where user action is
explained for HMI
1. Gas circuit system
2. Oil circuit system
3. Suction condensate drain systems
4. Supply air system
5. Ambient air recirculation
6. Chiller and chilled water pumping Unit

The system operation description described in detail below shall be read in conjunction with the latest
version of P&ID ADI10690.

3.1- Gas Circuit

Biogas is sucked into the intake valve SCV1 of the screw block SC1 through the inlet heat exchanger HE6 and
the gas filter CF1 (see also suction condensate drain system described below).

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 Gas inlet pressure, expected between 1 and 35 mbarg, is firstly detected by PT6, which can stop the
compressor in case inlet pressure reaches LL level of 0 mbarg. Gas is cooled down from 20-40°C to 4°C in HE6
which is a shell&tube plate type heat exchanger with chilled water in the shell side as cooling media. Chilled
water is provided by chiller and relevant chilled water pumping unit (see dedicated section below).

Downstream HE6, temperature transmitter TT15 detects gas temperature and gives warning if H value (i.e.
6°C) is reached, while it stops the compressor if HH (i.e. 8°C) temperature is reached. The H and HH value are
adjustable via HMI in the UCP.
Alarm setting of PT2 and PT6?
After being filtered by CF1 gas pressure is sensed by PT2, which gives the feedback to control the motor
speed and bypass valve thus regulating the gas flow delivered by the compressor (see the relevant section
below on “Suction Pressure Control”). In case sensed pressure reaches the LL level of -50mbarg the
compressor is tripped, as excessive vacuum is dangerous for the compressor’s operation considering that
oxygen can be sucked in from the atmospheric air through connections upstream screw block, which may
potentially lead to explosive conditions during compression. The complementary use of an oxygen analyzer
to detect oxygen content in the gas stream to be compressed is strongly recommended.

this value Gas

wasthen passes through the inlet valve SCV1, which description of operation is given in Appendix 1 of this
previouslydocument.
shared
to be 3.5 barg.
The screw block is oil injected, so during compression cycle the gas is mixed with oil in the screw block. Gas/oil
mixture flows into the gas/oil separator vessel SR1 where, firstly by mechanical action and secondly by
filtration through deoiling cartridges SF1-4, the residual oil is removed and pumped back into the screw block.
Compressed gas passes through MPV1 (Minimum Pressure Valve) once it has reached the minimum pressure
set point (i.e. 4.9 barg). MPV1 remains closed until pressure in the system builds up to 4,9 barg to allow oil
recirculation in the screw block through oil circuit and thus allow proper lubrication and cooling. After
reaching 4,9 barg MPV1 opens mechanically.

Gas then goes through the water/ gas cooler HE2. Here the gas is cooled down to a temperature of 45 °C by
cooling water supplied by User. A thermostatic valve TV3 is installed in the water circuit and is set to maintain
a temperature of 45°C on the discharge gas line from HE2, so that TV3 is mechanically regulated to allow
more or less cooling water flow and keep this temperature. Since the pressure dew point of the gas in the
discharge line is around 37°C a temperature of 45°C is suitable to avoid condensation. TV3 set point can be
adjusted manually. Method to change TV3 setpoint manually
At next stage the residual oil and particles present in the gas are removed by discharge filters CF3 and CF4.
The residual oil is drained by automatic condensate drains CDF1 and CDF2. Any details of automatic condensate
drain?
In the discharge line, before the gas outlet connection, temperature is detected by TT4, which has a warning
L set point (i.e. 42°C) and LL trip set point (i.e. 39°C). Pressure is detected by PT1 with H (i.e 6.5 barg) and L
(i.e. 5 barg) warning and HH (7.0 barg) and LL (4.7 barg) trip set points.

3.2- Oil Circuit

Most of the oil is collected at the lower part of the gas/oil separator SR1. Oil from the bottom of SR1 is
recirculated into the screw block by means of the differential pressure between the discharge and suction
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side. At the start up of the compressor proper recirculation is guaranteed by MPV1 which opens only when
a set pressure (i.e. 4.9 barg) is reached. How to verify oil circulation during startup?

Oil passes through thermostatic 3-way valve TV1, which is a mechanical auto-regulated type temperature
valve. The valve is set at a temperature of 95°C sensed upstream so that in case the temperature is higher
part of the oil flow is diverted to heat exchanger HE1 which cools the oil down by means of cooling water,
provided by User. Oil is then mixed and goes through oil filter OF1 -which retains all the impurities before
being re-injected in the screw block.

A small quantity of oil is collected by gas/oil separator cartridge SF1-4 during the last stage of filtration in the
gas/oil separator and is returned to the screw block suction side though the scavenge line and oil scavenge
visors SG1-4.
Details related to CR2 and SCLF1 are missing in oil
circuit.

3.3- Suction Pressure Control PT 2

In Local Mode operation, the compressor uses the suction pressure as feedback to control the motor speed
and bypass valve PCV1 opening thus varying the gas flow at compressor outlet depending on “Suction
Pressure Setpoint” set via HMI.

The components used for this purpose are:

• Inverter VSD and main motor M1

• PCV1 Gas Recycle Control Valve
• PT2 Suction Pressure Transmitter

For this control the Inverter VSD and the gas recycle control valve PCV1 operate jointly.

The inverter VSD regulates the compressor flow rate in the range of 100% down to approximately 50%. (PCV1
fully closed). Any data related to % VSD and Biogas flow rate/pressure
The screw block is selected to reach the design operating conditions, max flow 100% @ max discharge
pressure) given the minimum suction pressure, running at a certain speed. The inverter VSD varies the motor
speed and therefore compressor flow by varying the supply frequency.

If the suction pressure monitored by PT2 is higher than the set point, PCV1 is closed and the VSD increases
the frequency thus increasing the main motor speed provided that it is below the maximum allowable motor
speed.

Conversely, if the suction pressure decreases and goes below the set point, VSD decreases the frequency so
decreasing the motor speed provided that it is above the minimum allowable motor speed and consequently
the gas flow rate decreases.

In case the motor is running at minimum speed and the suction pressure continues decreasing, the PCV1
opens modularly and gas is recycled into the suction so that a stable suction pressure is maintained.

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is it PT6? or PDT1? please elaborate it
further?

3.4- Suction Condensate Drain System Low Low(LL) Setting?

The condensate drain system makes use of a level transmitter (LT1). It has 4 different thresholds, that is HH
(60%) /H (45%) /L (10%). Both HH and LL will trip the compressor whereas reaching H level SV2 opens, only
in case PT1 is above 1 barg , and SV7 opens actuated 3 way valve BV10 way from discharge side to CR1,
closing the wat from filter drain, so that water tank CR1 is pressurized in order to discharge the condensed
liquids. Discharging continues until L level is reached.

When SV2 opens at H level and starts discharging, after it reaches L level, it waits 90 seconds after which the
valve is forced closed.
Is the timer adjustable in HMI?
At each start of the compressor HH level of LT1 is inhibited for 90 seconds after which it is enabled.

3.5- Supply Air System

The package is equipped with a supply air system in order to pilot BV10 through SV7 and PCV1. This line has
an inlet filter (CF5) and a pressure switch PS1 with a low threshold (LL) that will trip the compressor if air
pressure gets lower than the setpoint (i.e. 5 barg). Alarm setting should be there.

3.6- Ambient Air Recirculation

The compressor has a motor driven fan EF1 in order to extract air when temperature gets higher than 30°C.
The fan will stop when ambient temperature reaches 15°C. TT12 is the temperature probe that drives fans.

Additionally, there is an analog gas detector AS1 inside the compressor which has 2 levels (H: 20% LEL; HH:
40% LEL).

When the gas detector reads for H level the fan is started. If gas concertation rises up to HH, then fan still
runs but compressor will trip. What happens when there is "LEL
methane LEL is 4%
sensor failure"? so why alarm is at
20%
3.7- Chiller and chilled water pumping Unit
Once compressor package is started, automatically also the water chiller and the chilled water pumping unit
are started. They are intended to provide chilled water as cooling media to HE6. Similarly, as the compressor
is stopped also the water chiller and pumping units are switched off. Compressor PLC gives the start and stop
command to the Chiller, which as its own standard manufacturer integrated controller, which in turn starts
/ stops the pumping unit. Water chiller is sized and designed to provide chilled water to the inlet heat
exchanger HE6 in a closed circuit. With respect to the chiller, the temperature of chilled water at inlet is 7°C
and at the outlet it is 2°C and water flowrate is approx.. 8178 liters/hour. The water chiller is water cooled,
with cooling water supplied by User, intended to be provided at 32°C at inlet of the chiller and coming out at
44°C at the outlet. For more details on the operation of the chiller and on its own integrated controls please
refer to the Operation and Maintenance Manual of the chiller.

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4. Operational prerequisites
Some manual operations and checks must be done by the plant operator as part of the necessary conditions
before starting the compressor package. They are listed below.

4.1- Manual checks

The following manual checks must be performed:

- Make sure that the main and auxiliary motors, the starting and control electrical panel (MCC & UCP)
are powered and that the automatic control mode has been selected;
- Make sure that all local stop and emergency buttons are reset;
- Make sure that the supply of instrument compressed air is available;
- Make sure that all manual valves are in the correct position;
- Make sure that cooling water is available;
- Make sure that chiller and chilled water pumping unit are powered and chilled water is available;
- Check that the oil level in the main gas / oil separator is correct. In case, top up.

5. Automatic Actions at Power Up

Once the system is powered up and no error on safety signals is detected, the compressor control system
performs automatically the following actions:

1. The suction pressure alarm on PT6 is inhibited.

2. The recycle bypass valve PCV1 is locked at fully open position.
Inst: where is
3. The following alarm/trips are also inhibited:
Remote Start/Stop
a. TTS1 LL (enabled after 1200 s from start command )
from AETP PLC.
b. TT4 all thresholds (enabled after 90 seconds from start command)
c. LT1 HH (enabled after 90 seconds from start command)
starts at what rpm?
how it will
6. Automatic Actions at Start Up increase? logic?
The Start Up of the compressor system is performed by pressing “START” key in the Local Operator Panel on
board of the compressor (Local control) or by start command from HMI in the Control panel (Remote control).

The following sequence is performed when the START button is pressed.

GV6 is a manual valve so will it always remain
1. Chiller is started; open?
2. The main motor starts up slowly. Gas is sucked into the inlet valve SCV1 which is initially closed but
is bypassed through GV6. Pressure builds up while MPV1 is initially closed until the minimum set
pressure is reached.
3. Solenoid Valve SV1 is energized so that gas from discharge passes through it and pushes the piston
P of the inlet valve (butterfly valve F spring loaded) so it opens fully. Pneumatic valve 2A is closed so
compressed gas flow from separator to suction is interrupted.
6 / 11 at how much
internal pressure
do you think starting the chiller and compressor the SV1 will
at the same time will allow to pass hot gas in to energize to open
compressor? because it will take some time to Piston P?
produce chilled water and then chill the biogas
from HE6
 what speed value?

4. When minimum pressure (i.e. 4.9 barg) is reached in the compressor, MPV1 opens and allows gas to
flow to the outlet. PCV1 is fully open so gas is recirculated in the system.
5. When the motor reaches the minimum speed, then:
the PCV1 starts closing and the motor speed is increased to the set value by the inverter and then
controlled by suction pressure set point;
Inst: Remote Start/
6. Upon reaching the load condition, the suction pressure alarm from PT6 is enabled.
Stop from AETP
(Customer) PLC
There is no check of Lube oil pressure also.
7. Automatic Actions at Stop and temperature in startup
Normal Stop of the compressor can be initiated by pushing the “Stop” button in the Local Operator Panel on
board of the compressor (Local control) or by stop command from HMI in the Control panel (Remote control)

The following sequence is performed when “Stop” is pressed on the HMI display:

1. The motor speed goes down to the minimum speed;

2. The gas recycle valve PCV1 is fully closed (Stop by Stop command)
3. Solenoid Valve SV1 is de-energized so that gas from the discharge separator is not allowed to
pass through it. The pressure is thus removed from pneumatic piston P bleeding to suction and
automatically the butterfly valve F closes (spring loaded). Through the pneumatic valve 2A gas
from the gas/oil separator is depressurized to suction down to a minimum unload pressure of
approx.. 2.0/2.5 barg through the restrictor GV3 connected to the suction. This pressure,
sufficient to circulate the oil during the unload/stopping phase, is achieved by adjusting
adequately the restrictors GV3 and GV6.
4. After 180s from reaching minimum speed the compressor motor is switched off.
5. After the main motor is stopped a Blowdown timer (60s) is activated, during which the Control
system will prevent a new restart from being initiated. Once this time has elapsed, the
compressor can be restarted again.
only timer or any action will also take place
during this event?
8. Trip and Emergency Shutdown
The compressor assembly is protected by hard-wired safety relay circuit which monitors the critical process
trips. This circuit operates as part of a Safety Instrument System (SIS) and does not depend on PLC control
system.

The SIS uses a safety relay to ensure a safe shutdown of the compressor upon a trip condition, regardless of
the PLC operation. When a trip is activated, the supply circuit of the main motor is opened thus stopping the
main motor immediately.

The TRIP/FAULT message will be displayed on all Synoptic windows.

The hard-wired trips are as follows:

• High High Discharge Temperature (TTS1), TAHH-1

• Low Low Inlet Pressure (PT2), PALL

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 Inst: Please confirm
SIL certification of
ESD loop
The ESD signals can be generated by:

• EHS1: local panel emergency stop pushbutton

• EHS2/3: electrical and control panels emergency stop pushbuttons
• External plant ESD signal

When a trip/emergency condition occurs, the relevant safety relay will be latched in the trip state. This relay
can be re-energized by pressing the RESET ALARMS button on the ALARMS window, after all relevant trip
causes have been removed.

9. Control modes Inst: Remote Reset

Compressor has two different modes: from AETP
(Customer) PLC
• LOCAL mode
• REMOTE Mode

9.1- Local Mode

The capacity is controlled by inverter and one by-pass valve based on the inlet pressure, set point is
set via HMI (no possibility to change it from remote).

The logic is controlled by internal PID on the PLC.

PID set point is related to the INLET pressure and the process variable is read by the inlet pressure
transmitter PT2.
The outputs of the PID are two:

 Speed command to the VSD;

 Open/close command to the PCV Valve.

1° condition = INLET pressure PT2 (PV) ABOVE the SET POINT (SP)

PV>SP PCV command INVERTER speed NOTE

Type of signal 4-20mA 4-20mA

Action Increase (to closing Increase (if PCV
position) already fully closed)
Result Valve completely Maximun speed
close (100%)

2° condition = INLET pressure BELOW the SET POINT

PV<SP INVERTER speed PCV command NOTE

Type of signal 4-20mA 4-20mA

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 Action decrease to min Decrease (to open
speed position if VSD is
already at its
minimum speed)
Result Minimum speed Valve completely valve fully open is
open (0%) 0% and fully close
is 100%)

9.2- Remote Mode

When compressor is set in remote mode, client will be able to module the capacity by means of external 4-
20 mA signals.

One signal will regulate the proportional command for opening/closing of the PCV1. Once the PCV1 is
completely closed and compressor is running at minimum speed then another signal can drive the VSD (4-20
mA) regulating its speed.

Similarly once the compressor is running at minimum speed, then PCV1 can be regulated (opening).

Unit will be started only via hardwired signals

10. Signals for customer

Inst: In our case,
Thera are several signal interfaces between VSD/PLC to customer’s control system.
remote mode for
Hardwired Signals: capacity control shall
Inst: not be used. Please
From customer’s control system to PLC:
Run/Stop mention that this is an
• Run/Stop command to the VSD- Hardwired. command to optional part reserved
• 4-20mA analogue to VSD for speed control. Compressor's PLC for future use only.
• 4-20mA analogue for PCV control

From PLC to customer’s control system:

• RGF: general fault, NO free voltage - Hardwired

• RES: emergency stop, NO free voltage - HardwiredInst:
1. Remote Start/Stop
2. Remote Reset
As well as the hardwired signals there will be communication3.through Modbus
Run/Stop RTU (Slave). Relevant
Indication
Communication List has been shared and is available. 4. RS485 Modbus serial
communication

11. Safety Devices

Safety, control and regulation devices that protect the assembly from exceeding the allowable pressure and
temperature as well as from emergency conditions are shown in the following table.
9 / 11
 just need confirmation that all the PLC warning
and trips are available in the below table?

Tag Description Function Warning Trip

EHS1 Emergency pushbutton on Emergency stop from compressor.

--- ---
board
Emergency

EHS2 Emergency pushbutton on Emergency stop from electrical panel.

electrical panel --- ---

How can we distinguish that ES

EHS3 Emergency pushbutton on Emergency stop from control panel.
control panel
command comes
---
from ---
Customer PLC or compressor's
control panel

Connected to PLC.

High temperature protection on gas/oil circuit:

 High temperature 105 °C 110 °C

 Low temperature
83 °C 70 °C
TTS1 Temp. Probe PT100
Temperature

Connected to safety temperature switch.

High temperature protection on gas/oil circuit:

 High temperature --- 115 °C

TE1 Temp. Probe PTC Main motor high temperature protection. please
--- give the trip value

TT15 Temp. Probe PT100 High temperature protection downstream HE6 6 °C 8 °C

TT4 Temp. Probe PT100 Low temperature protection outlet 42 °C 39 °C

TT20 Temp Probe PT100 High temperature protection oil circuit 100°C 120°C

PT1 Pressure Transducer Delivery gas pressure control:

 High pressure control (H/HH)

 Low pressure control (L/LL)
6.5 barg 7 barg
NOTE:
Pressure

5 barg 4.7 barg

Process Unload (P.U.): 6.8 barg:
Compressor is stopped at this pressure
according to “Automatic Actions at Stop”
procedure. This is to prevent compressor
to trip at 7 barg (HH).
PT2 Pressure Transducer Inlet gas pressure control downstream HE6 and
--- -50 mbarg
CF1

10 / 11

what are the steps

for compressor
unload?
  Low pressure (LL)
PT6 Pressure Transducer Inlet gas pressure control
---- 0 mbarg
 Low pressure (LL)

PT3 Pressure Transducer Internal gas pressure control

 High pressure (H/HH) 7.5 barg 8 barg

PSV1 Safety valve PED High pressure protection gas/oil receiver,

--- ---
overcomes PT3 failure (set to 8 barg)

Differential pressure SF1 filter clogging control

PDT1 500 mbar ---
transducer

Differential pressure OF1 filter clogging control

PDT3 transducer
1500 mbar ---

LT1 Condensate level Condensate level at suction:

transmitter 60%

Level

High level (HH)

45%
 Discharge (H)
 Finish discharging (L) 10%

Inst.
What about other transmitters warning and
trip valve.
1.PS1
2.PDT-2
3.PDT-5
4.PDT-6
5.TT12
6. PCV1 If PCV performs malfunction.

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