Control systems for Turbomachinery and beyond!

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Control_Care slide offshore

Engineering services for Turbomachinery controls and beyond!

Projects

Our reference list highlights below

India - FPSO
ref86-IN-1349

Project description
Pre-commissioning and commissioning work of the unit control
panels controlling two screw compressor units including the auxiliary systems. 

Scope and unit(s)
Instrumentation and Controls (I&C) activities for control panel checkout, cold and hot commissioning and compressor start up. Activities included testing and commissioning of instrument loops, switches, valves, variable speed gear and e-motor. Including compressor start-up and shutdown sequence testing.

Plant type
FPSO, Eastern offshore, India

Control platform
Two compressor packages. Each compressor unit operates individually, independent and includes following main items:
- Motor as main drive with fixed speed, speed increasing gear,  each train consists of two screw compressor stages
- A unit control panel, equipped with Siemens PCS7 type PLC system with local HMI
- Oil supply unit (internal, as part of compressor unit base frame)
- An acoustic enclosure with two fans for forced ventilation for the compressor unit
- Fire and gas detection system, Hima HiMatrix ESD system

Netherlands - Biorefinery
35511   Alco Energy NL

Project description
Full PLC and control panel upgrade of three Burner Management Systems (BMS) used in dryers.

Scope and unit(s)
Upgrade and reverse engineering of three existing Burner Management Systems (BMS), by replacing the obsolete Siemens S7-300 (Step7) control system with Siemens S7-1200 (TIA Portal) control system including the local panels.

Plant type
Biorefinery

Control platform
The logic is implemented on Siemens F-PLC 1215 hardware and SIMATIC S7 TIA Portal software platforms. The hardware platform communicates through Profibus DP with the DCS for visualization/operation purposes, and ethernet communication to Remote Fail Safe I/O, and Profinet communication to the Fuel-Air-Ratio controller (KS98-2) and through WinCC to a dedicated HMI TP1200 Comfort with operator displays.

Finland - Refinery
1369   Neste FI

Project description
Control system replacement in Valmet DNA for two stage steam turbine driven axial air compressor for Fluid Catalytic Cracking Unit (FCCU).

Scope and unit(s)
Design, engineering and replacement of existing control system, (pre)commissioning and start-up assistance. Supply of antisurge control, performance control on Valmet DNA DCS, integrated solution, replacing CCC controllers, brownfield.

Plant type
Refinery

Control platform
Control-Care’s steam turbine application (STCA), antisurge application (ACA), performance control application (PCA) onto ValmetDNA, Honeywell EPKS HMI and Valmet HMI.

Nigeria - FPSO
1358  COMMISSIONING FPSO NIGERIA p1

Project description
Compressor antisurge control and vibration monitoring system upgrade for motor driven flash gas and export gas compressor.

Scope and unit(s)
Project management, design, engineering, supply, offshore installation, commissioning and startup of compressor antisurge control and vibration monitoring systems. Scope includes removing existing and aging controls equipment and rejuvenate with new PLC and VMS control systems.

Plant type
Floating Production, Storage and Offloading fascility

Control platform
Control-Care Compressor ACA Antisurge Control Applications on Rockwell Allen-Bradley ControlLogix PLC, FactoryTalk (RS View) HMI and Bently Nevada 3500 Vibration Monitoring System, replacing legacy Rockwell Allen-Bradley PLC5.

Singapore - FPSO

Project description
Field and commissioning services for 7 compressors for an FPSO going to an ultra-deepwater salt field, offshore Brazil.

Scope and unit(s):
Cause and effect testing, sequence testing and general commissioning activities to get unit ready for the clean up run. Activities included additional logic for water injection to cool the machine during a nitrogen run.

Plant type
Floating Production, Storage and Offloading fascility

Control platform
Rockwell Allen Bradley redundant ControlLogix PLC with regular IO and redundant safety IO modules. FactoryTalk on Stahl HMI’s.


Indonesia - Air Separation Plant

Project description
Radial compressor surge protection, detection and alarming

Scope and unit(s):
Control-Care's Surge Detection System for a centrifugal compressor. The system produces compressor surge detection alarms to DCS and MCC for the Main Air Compressor.

Plant type
Air Separation Unit (ASU)

Control platforms
Control-Care Surge Detection System (simplex), MAN ES centrifugal compressor, Yokogawa Centum VP DCS

Sweden -Refinery
Ref79B-SE-1359

Project description
Antisurge control application (ACA) within Honeywell C300

Scope and unit(s):
Replacing existing obsolete Hartmann&Braun Protronic PS controller with an integrated solution using a C300-20 Honeywell Experion release 520.2 system. C300 cabinet hardware and supply of compressor software logic and antisurge control application (ACA) for 1 hydrogen recycle gas compressor

Plant type
Refinery

Control platforms
1x Antisurge Control Application (ACA) for hydrogen recycle gas compressor, implemented within C300-20 Honeywell Experion release 520.2.

Netherlands - Nitrogen Plant
1350   Zuidbroek

Project description
Commissioning and site support services for eight Unit Control Panels (UCP).
Functional and safety testing of the logic and controllers, surge verification/validation and controller tuning for all machines.

Units: 
- 3 air compressors, 6 stage integrally geared type with interstage cooling,
- 3 nitrogen compressors, 7 stage integrally geared type with interstage cooling,
- 2 reinjection compressors, single stage barrel compressor.

Plant type
Nitrogen plant

Control platforms
Each unit has its own UCP containing Siemens S400 H system (redundant) CPU’s running PCS7 V9.0 SP2 for compressor control and protection. Also included Baker Hughes - Bentley Nevada BN3500 MMS system for bearing vibrations and temperatures.

Indonesia - Power Plant
1370   Triguna

Project description
Commissioning and site support services to engineering and procurement contractor Triguna Mandala (TGM) for gasturbine commissioning support on DCS. The DCS solution replaces the aging Ovation DCS by Emerson. Gasturbine is Westinghouse make (now Siemens), brownfield

Plant type
Power plant

Platforms
 -
Siemens Westinghouse W501D5A gas turbine.
 - Brush generator
 - Emerson Ovation, Honeywell Experion C300-20

Germany - Chemical Plant
Ref75   1352   DE TMC

Project description
Project management, engineering, documentation and software applications delivery for the replacement of a steam turbine driven nitrogen compressor with an electric motor driven six stage integrally geared centrifugal compressor.

- Antisurge Control Application (ACA) for an integrally geared nitrogen compressor with sideloads.
- Performance Control Application (PCA) controls the IGV position setpoint based on desired main process value whilst respecting various process/machinery limitation values.
-Compressor operating points per stage visualization (compressor maps).
- Realtime compressor power calculations.
- Realtime train power balance comparison between motor and compressor

Plant type
Chemical - Nitric Acid 

Platforms
Control-Care compressor Antisurge Control Application (ACA) and Performance Control Application (PCA) within a redundant Yokogawa Centum VP process control platform.

Iraq - Refinery

Project description:
Commiissioning support for three Tank Vapour (TV) compressor trains including compressor control systems troubleshooting mechanical commissioning support compressor startup readiness.
- Compressor control systems troubleshooting
- Mechanical commissioning support
- Compressor startup readiness
Project consisted of 3 trains with each train having 1 Tank Vapour (TV) radial compressor, 1 LP radial compressor  and 1 HP radial compressor. Compressor auxilliary commissioning included  lube oil system and dry gas seal system.

Plant type
Refinery

Platforms
Siemens S7 PCS7 for compressor control and BH-BN3500 vibration monitoring system

Pakistan - Ammonia Plant

Project description:
Field support services for replacement of control system to improve the protection and reliability of the compressor train.
- Replacement of the TurboLog controller.
- Replacement of the steam turbine overspeed protection device.
- Replacement of the tail gas expander overspeed protection device.
- Additions to the vibration monitoring system to improve machine reliability.
- Overspeed trip tests.
- Air compressor surge test

Plant type
Ammonia plant - Nitric Acid area

Platforms
OEM provided Gebhardt Automation BlueLine2 Duplex controller.

Project description
A packaging plant seeking the possibility to apply a software change to the existing steam turbine driven generator set control system. Existing controller configuration was providing poor speed  response not sufficient for stable and reliable speed control of the unit during synchonisation to the grid. Control-Care was requested to investigate, reverse engineer, implement, document and test the software modification. Site implementation was realized through an implementation procedure and took place without any flaws

Plant type
Packaging plant

Platforms
Steam turbine control: Siemens S7 PLC with WinCC HMI

Belgium - Packaging Plant
Belgium - Ammonia Plant

Project description
An integrated Honeywell/Control-Care solution for the replacement of the existing PLC based compressor control system for the Nitric Acid production facility. Proposed, and realized, was an integrated solution based on Honeywell’s C300 control platform. Control-Care proposed a field proven technical solution, based on Honeywell’s C300 architecture and Control-Care’s compressor and steam turbine control applications. Proposed compressor and steam turbine control solution includes:

  • 1 ea Steam Turbine Control Application for the steam turbine drive and
  • 1 ea Antisurge Control Application for the air compressor 

Plant type
Ammonia plant - Nitric Acid area

Platforms
Compressor control: Honeywell C300 with Control-Care's Antisurge Control Application (ACA)
Steam turbine control: Honeywell C300 with Control-Care's Steam Turbine Control Application (STCA)

Brunei - Ammonia Plant

Project description
Field support and supervision for hot commissioning and startup of compressor anti-surge control systems for 5 compressors involved in the ammonia and urea production (CO2 compressor). For each compressor, natural gas, syngas, ammonia refrigeration, air and CO2 respectively, a dedicated fault tolerant PLC type controller with purposely built control applications was commissioned. In addition, control for 6 steam turbines for Syngas/Refrigerant/Air/CO2 compressors, Generator and boiler feedwater pump were part of the scope as well. Three of these steam turbines also have extraction control enabled. The generator turbine and the syngas compressor steam turbines both feed the MP steam header for the ammonia production through their extraction stage. The stability of the MP steam header was key to be kept at 50 Bar, only small deviations were allowed (+ or- 0.2 Bar), any larger deviation greatly affects the efficiency of the ammonia reactors. It was a challenge to balance the speed control and the extraction control to achieve both a constant speed and a steady extraction pressure with the given margins but ultimately for the 2 units in mentioned (generator turbine and syngas turbine), it was successful.  The scope of this project was limited only to speed control for the turbines and anti-surge control for the compressors, but was a technical challenge in relation to the tight margins for the extraction control pressure.

Plant type
Ammonia plant

Platforms
Anti surge control: Micronet with GAP4 software
Speed control: 505D (Speed control) or 505XT (Speed control + extraction)
Actuators: Woodward varistroke for HP and LP valves on steam turbines

Netherlands - Refinery

Project description
Responsible to deliver technical expertise in process control and automation for the site projects. This includes the development, support, and maintenance of the process controls and the instrumented protection functions, with the objective of ensuring a safe, reliable, environmentally sound, optimized, and energy-efficient day to day operation. Also includes keeping up to date the related controlled documents: Process Control Narratives (PCN), Instrument Safeguarding Narratives (ISN), and Cause and Effect matrices.

Plant type
Refinery

Platforms
Multiple brands used for instrumentation devices and actuation devices. Including Honeywell DCS based control system for steam turbine control and generator load control

Bosnia - Steel Mill

Project description
From a compressor control optimalization study performed in 2019 by Control-Care, to project execution phase in 2021 for an electrification project where a steam turbine was replaced by an electric motor driving an air compressor. Control-Care scope of supply included:
(1) Modernize the actuator on the "Snort" valve to allow for automatic operation of the snort valve (no longer in manual by operator) .
(2) Existing steam turbine and compressor control PLCs were removed completely and a single hardware platform to be used for Motor and Compressor control (ABB AC800M).
The benefit of using an integrated solution was easier implementation, interfacing and maintainance rather than maintaining (some of) the existing systems and continue having multiple vendor systems.

Plant type
Steel Mill - Blast furnace

Platforms
Control-Care applications for compressor loadsharing, antisurge and performance control have been implemented on ABB AC800M automation platform. 

Germany - Power Plant

Project description
Control-Care supported a turbomachinery original equipment manufacturer (OEM) during the final commissioning and startup activities following greenfield installation, cold commissioning of all instrumentation, valves and controls, hot commissioning, and start up.  Control-Care's support activities also included operational support after unit start up.

Plant type
Power plant

Platforms
Multiple brands used for instrumentation devices and actuation devices. Including Siemens PLC based control system for steam turbine control and generator load control

Philippines - Power Plant

Project description
Control-Care has successfully provided augmented reality (AR) remote assistance services for calibration, troubleshooting and testing of the main steam control valves on two 150MW steam turbine generator (STG) units for AboitizPower subsidiary Therma South, Inc. in Davao, Philippines. Due to covid travel restrictions our engineers could not be present on site. This remote assistance solution has enabled the end-user to still carry out the required activities effectively and accurately, without jeopardizing the turn-around schedule. The end-user’s engineer was carrying the AR remote assistance tool, whilst the Control-Care expert was monitoring and providing instructions from the headquarters in The Netherlands. The AR remote assistance tool is suitable for harsh industrial environments and ensures a safe working environment since it enables the user to still operate “hands-free”.

Plant type
Power Plant

Platforms
Field instrumentation and valve actuators

United Kingdom - FPSO

Project description
From a compressor control optimalization study performed in 2019 by Control-Care, to project execution phase in 2021 for an FPSO located in the United Kingdom. Involved in this study and execution phase were two variable speed centrifugal compressors used for oil gas separation installed on board.  Essential control system modifications were made to the 25+ year old control philosophy and PLC system for both compressors to improve operability of the units, increase production and to reduce downtime of the units due to unexpected process trips.  The MP1&2 compressor performance controller was reconfigured to maintain suction header pressure of MP1 compressor instead of MP2 compressor discharge pressure. The HP compressor performance controller was reconfigured to maintain suction header pressure instead of HP compressor discharge pressure. The scope included serial interface modifications required for visualization of PV, SP adjustments and compressor flow calculations on to the DCS. The new control strategy was flawlessly implemented offshore following a thorough (remote) FAT using the end user’s spare controllers with end user’s PLC software staged in Control-Care’s premises.  

Plant type
Floating Production and Storage Offloading (FPSO)

Platforms
Rockwell Automation - PLC5 turbomachinery control system

Uzbekistan - Gas Processing plant

Project description
Executed work involved review and analysis of operating values in accordance with trends and process gas compressor unit event logs. Functional check of alarm, protection system, surge control system, operation of control valves. Required sensors and cables of gas compressor unit were demounted and re-installed together with the local mechanical engineer. Functionality of oil supply system was checked and documented. The project was finalized after commissioning of the control system and support during compressor start up.

Plant type
Gas Processing Plant

Platforms
Siemens S7 PLC based compressor control system.

Norway - Power Plant

Project description
Control-Care supported an Independent Service Provider ("ISP") during a minor steam turbine inspection / maintenance. Control-Care's specialist(s) were assigned, via an independent service provider (mechanical), to the turnaround team during a scheduled minor inspection. The scope included removal, cleaning & inspection of mechanical parts of the turbines. Installation and adjustment of all instrumentation, valves and controls, re-assembly of all mechanical equipment and start up.  Control-Care's support activities also included operational support after unit start up.

Plant type
Power plant

Platforms
Multiple brands used for instrumentation devices and actuation devices. Including Siemens based control system for steam turbine control.

Netherlands - Air Separation Plant

Project description
Control-Care's specialist(s) were assigned, via an Independent Service Provider (mechanical), to the turnaround team during a major nitrogen compressor overhaul. Turnaround services included (dis)connecting of E-Motor, IGV's and PCV&ACV, oilpump(s) and other transmitters such as pressure and temperature transmitters on coolers and compressor. The work was performed under supervision and direction of the independent service provider and included troubleshooting,  system I/O checks and loop checks, software functional and interlock testing and to provide operational support as the plant was re-started for production.

Plant type
Air separation plant

Platforms
Multiple brands used for instrumentation devices and actuation devices.

Angola - FPSO

Project description
Trouble shooting and diagnose fuel metering valves used on gasturbine(s) after oxidation problems had been reported. Inspect the current setup, advise root cause and advise on preventive actions. 

Plant type
Floating Production, Storage and Offloading  (FPSO) facility.

Platforms
Gas and Liquid fuel valve metering skid hardware and OEM support software.

Singapore - FPSO

Project description
Control-Care successfully supported the compressor OEM with I&C works in preparation for a FAT of a three-stage centrifugal compressor on an FPSO. Our scope for the OEM included the testing and support services for Inconel 625 cladding of casing and covers, Fix Speed Electrical Motor, Gear Box, Lube Oil System, Couplings for HS and LS shaft, Seal Gas Panel, Unit Control Panel (UCP), Anti-Surge Control Valves and Suction Throttling Valves. The FPSO, currently under construction (June 2021), will be capable of processing 90,000 barrels of crude oil per day, 75 million cubic feet of gas per day, 120,000 barrels of water injection per day and have a storage capacity of 900,000 barrels of crude oil.

Plant type
Floating Production, Storage and Offloading  (FPSO) facility

Platforms
Various control system brands, field devices and unit control panels for LP Gas Compressor A/B, HP/Main-B gas compressor and Fuel Gas Compressor

Netherlands - Chemical Plant

Project description
Control-Care's DCS specialist(s) were seconded, via the main automation contractor, to the end user's project team during a major DCS control system hardware and software upgrade. The DCS control system's main hardware was upgraded. The PC based operator and engineering workstations were upgraded to a server and thin client architecture. The work was performed under supervision and direction of the main automation contractor and included firmware downloads, software patches and modifications, control system configuration and troubleshooting,  system I/O checks and loop checks, software functional and interlock testing and to provide operational support as the plant was re-started for production.

Plant type
Chemical plant

Platforms
Valmet DNA ACN controlller family

Norway - Chemical Plant

Project description
Project management, engineering, documentation and hardware delivery for the replacement of the existing surge detection system for an axial air compressor and an NOx compressor. The existing system will be replaced with a new, triple redundant, safety PLC which will run independently in a two out of three-selection scenario and running Control-Care's Surge Protection Application ("SPA"). Included are supply of control system enclosure and pressure and temperature transmitters dedicated to surge protection of the two compressors.

Plant type
Chemical - Nitric Acid 

Platforms
CC Compressor SPA Surge Protection Application on triple redundant Rockwell Automation's Compact GuardLogix PLC 

Belgium - Propane Dehydrogenation Plant

Project description
Design, engineering, supply, commisioning and startup of compressor antisurge and performance control systems for three new, different-make centrifugal (heat pump, reactor effluent and refrigeration) compressors

Plant type
Propane Dyhrogenation - Polypropylene

Platforms
CC Compressor ACA Antisurge Control Applications and PCA Performance Control Applications on redundant Honeywell PKS Experion DCS C300-20 controllers

Belgium - Chemical Plant

Project description
Design, engineering, supply, commissioning and startup of compressor antisurge and performance control systems for one recycle gas compressor and one process air compressor

Plant type
Chemical

Platforms
CC Compressor ACA Antisurge Control Application and CC PCA Performance Control Applications on Siemens S7-400 redundant. Siemens WinCC HMI

Romania - Biomass Power Plant

Project description
Commissioning and startup assistance for steam turbine generator set after overhaul

Plant type
Biomass Power Plant

Platforms
Turbolog Turbine Controller. Braun Overspeed Protection Device. Woodward Automatic Voltage Regulator SPM-D10B. Siemens Digureg Digital Excitation Control System. Siemens Siprotec 7UM62 Generator Protection. Siemens S7-400 and -300f for Auxiliary Controls. Siemens TP1500 Comfort HMI

Netherlands - Training Compressor Controls

Control-Care provided an interactive training course to a team of engineers at Chemelot park in Geleen. Dynamic compressor simulation was used to demonstrate compressor behaviour, surge detection and compressor control applications. Sharing turbomachinery controls knowledge and insights directly to the team enabled the engineers to apply insights to their own practices.

Plant type
Fertilizer

Platforms
Third party compressor controls equipment (CCC)

Italy - Biomass Power Plant

Project description
Commissioning and startup assistance for steam turbine generator set after major overhaul

Plant type
Biomass Power Plant

Platforms
Turbolog Turbine ControllerBraun Overspeed Protection Device. Woodward Automatic Voltage Regulator SPM-D10B. Basler DECS-250 Digital Excitation Control System. Siemens Siprotec 7UM62 Generator Protection. Siemens S7-300 and -300f for Auxiliary Controls. Siemens MP-277 HMI

Morocco - Phosporic acid mining and production

Project description
3rd Control system upgrade for a steam turbine driven air blower including steam turbine speed control, overspeed protection and retrofit of turbine valve actuation

Plant type
Phosporic acid mining and production

Platforms
CC Steam turbine control application on Siemens S7-400, Woodward overspeed prevention and Rexa actuators

Netherlands - Nitric Acid Plant

Project description
Design, engineering, supply and commissioning and startup of control systems for one air compressor, one NOx compressor, including compressor efficiency calculations, performance deviation and monitoring and back-flow detectors

Plant type
Nitric Acid plant

Platforms
CC Compressor ACA Antisurge Control Applications and STCA Steam Turbine Control Application on redundant Rockwell Allen-Bradley ControlLogix PLC, control cabinet, operator/engineering station with Iconics HMI software and galvanic converters

Netherlands - Refinery

Project description
Control system upgrade for a steam turbine driven generator

Plant type
Refinery

Platforms
CC Steam turbine control application on Honeywell C300-TMC platform

Netherlands - Refinery

Project description
Engineering, supply, commissioning and startup of control system upgrade for a steam turbine driven generator

Plant type
Refinery

Platforms
CC STCA Steam Turbine Control Application on Honeywell PKS Experion C300-20 (redundant)

Ghana - Gas Compression Station

Project description
Control system commissioning and startup for three SGT400 gas turbine driven compressor trains

Plant type
Gas Compression Station

Platforms
Siemens PCS7
Bently Nevada 3500 vibration monitoring

Belgium - PTA Plant

Project description
BDEP basic design engineering package (select and define study) for replacement of control and protection systems for multiple steam turbines, expanders and compressors

Plant type
PTA Plant

Platforms
CCC Series 4 
Honeywell GUS/Experion

Norway - Ethylene Plant

Project description
FEED study (Front End Engineering Design) for replacement of control and protection systems for one steam turbine cracked gas compressor train, one motor driven ethylene compressor, one motor driven propylene compressor and one expander of different brands, and for 7 reciprocating compressors

Plant type
Ethylene Plant

Platforms
Woodward Micronet for steam turbine control and compressor (antisurge) control Siemens Protronic for compressor antisurge control
Bently Nevada 3500 vibration monitoring
Hoerbiger RecipCom for compressor monitoring

Kazakhstan - Oil and Gas Treatment Plant

Project description
Long term service agreement (LTSA) support for control and protection systems on critical rotating equipment, including multiple flash gas compressors, sales gas compressors, expander compressor trains, combustion air compressors, and steam turbines

Plant type
Oil and Gas Treatment Plant

Platforms
CCC Series 3+ compressor antisurge controllers
CCC Series 5 compressor antisurge and loadsharing control
CCC Traintools
GE Fanuc 90-70 PLC
Proficy and Cimplicity HMI
GE Bently Nevada vibration monitoring systems

United Kingdom - Chemical Plant

Project description
Design, engineering and supply of a unit control panel for a new CO2 compressor 

Plant type
Chemicals Plant

Platforms
CC Compressor ACA Antisurge Control Application and PCA Performance Control Application on Siemens S7 PLC
GE Bently Nevada 3500 vibration monitoring

Bahrain - Gas Compression Station

Project description
Control system commissioning and startup for three SGT400 gas turbine driven 2-stage compressor trains

Plant type
Gas Compression Station

Platforms
Siemens PCS7, Bently Nevada 3500 vibration monitoring

Azerbaijan - Onshore facility

Project description
Control system commissioning for two electrical motor driven flash gas compressor trains

Plant type
Onshore facility

Platforms
CCC Series 5 Vanguard for antisurge, performance and loadsharing control
Siemens PCS7 for compressor auxiliary control, Bently Nevada 3500 vibration monitoring system

Malaysia - Synthesis Plant

Project description
BDEP basic design engineering package for replacement of control and protection systems for two recycle gas compressors and one expander

Plant type
Synthesis Plant

Platforms
Bently Nevada 3500 and system 1 vibration monitoring (replacing Bently Nevada 3300) Shell CASC Compressor AntiSurge Control on Yokogawa Centum DCS (replacing basic DCS antisurge control)
Shell CASC Compressor Anti Surge Control trip in Honeywell IPS (replacing Protronic antisurge trip system)

United Kingdom - FPSO

Project description
Control system commissioning and startup of two motor driven booster compressors and two motor driven export compressors in both Singapore and UK North Sea

Plant type
FPSO

Platforms
Siemens PCS7 for compressor controls Bently Nevada 3500 vibration monitoring system

United Arab Emirates - Gas Compression Station

Project description
Performance and surge testing  for three compressor stations, each with three motor driven variable speed two-stage compressors with parallel loadsharing

Plant type
Gas Compression Station

Platforms
CCC Series 5 Vanguard for antisurge, performance and loadsharing control Siemens PCS7 for compressor auxiliary control Bently Nevada 3500 vibration monitoring system

Kazakhstan - Power Plant

Project description
Commissioning and startup of two 32MW steam turbine generator sets. Including full comprehensive site acceptance testing procedures and operator training.

Plant type
Power Plant

Platforms
GE Fanuc 90-70 PLC Proficy and Cimplicity HMI

Netherlands - Olefins Plant

Project description
Consultancy services, design, engineering and procurement support during define and execute phases for replacement of various control and protection systems and instrumentation for five steam turbine compressor trains

Plant type
Olefins Plant

Platforms
Woodward 5009 FT steam turbine speed control Woodward  Protech GII overspeed protection Voith 2oo3 trip block and I/H actuators

Netherlands - Paper Mill

Project description
Installation, commissioning and startup of instrumentation, electrical and control systems of a 20 MW steam turbine (generator drive) after (major) overhauls

Plant type
Paper Mill

Platforms
ABB Control Systems

Morocco - Phosporic acid mining and production

Project description
Control system upgrade for a steam turbine driven air blower including steam turbine speed control, overspeed protection and retrofit of turbine valve actuation

Plant type
Phosporic acid mining and production

Platforms
CC Steam turbine control application on Siemens S7-400, Woodward overspeed prevention and Rexa actuators

Netherlands - Hydrocracker

Project description
FEED front end engineering design study -including project budget, RFQ documents and vendor selection- for an instrumentation and controls retrofit -including turbine inlet valve actuation modernization- of a steam turbine driving a hydrogen recycle gas compressor

Plant type
Refinery-Hydrocracker

Platforms
Third party buyouts

United Arab Emirates - Olefins plant

Project description
Control System Solution for two instrument air compressors including air driers

Plant type
Olefins plant

Platforms
CC Compressor ACA Antisurge Control Application and PCA Performance Control Application including air dryer logic application on Honeywell C300 DCS platform

Netherlands - Paper mill

Project description
Installation, commissioning and startup of instrumentation, electrical and control systems of a 20 MW steam turbine (generator drive) after major overhaul

Plant type
Paper mill

Platforms
Electrical and instrumentation works during a turn around

Finland - Olefins plant

Project description
Control system upgrade for one motor driven heat pump compressor (GB12901), including antisurge control and performance control, for PolyPropylene Expansion Project

Plant type
Olefins plant

Platforms
CC Compressor ACA Antisurge Control Application and two CC Compressor PCA Performance Control Application on Valmet DNA DCS

Finland - Olefins plant

Project description
Compressor Control system expansion for Compressor temperature (Quench) control integrated with antisurge control applications

Plant type
Olefins plant

Platforms
Five CC Compressor PCA Performance Control Applications on Valmet DNA DCS

France - Ammonia plant

Project description
Control system upgrade for one motor driven air compressor, including antisurge control

Plant type
Ammonia plant

Platforms
CC Compressor ACA Antisurge Control Application on Emerson DeltaV DCS

France - Ammonia plant

Project description
Control system ACA software upgrade for 3 process stage ammonia and 4 process stage synthesis gas compressor

Plant type
Ammonia plant

Platforms
CC Compressor ACA Antisurge Control Application on Emerson DeltaV DCS. Existing antisurge applications for ammonia and syngas compressors have been upgraded to same revision level as for the Air Compressor

Finland - Olefins plant

Project description
Control system upgrade for four steam turbines and various single and multistage compressors, including compressor antisurge control and steam turbine speed control

Plant type
Olefins plant

Platforms
CC Compressor ACA Antisurge Control Application and CC's STCA Steam Tubine Control Application on Valmet DNA DCS platform

France - Ammonia plant

Project description
Control system upgrade for three steam turbines driving compressors

Plant type
Ammonia plant

Platforms
Woodward 505 steam turbine control Woodward Protech TPS overspeed protection. Voith 2oo3 trip block and converters

India - Steel plant

Project description
Control system commissioning and startup of motor driven booster air compressor for air separation application

Plant type
Steel plant

Platforms
Antisurge control in Siemens S7-400 Bently Nevada 3500 vibration monitoring system

India - Refinery

Project description
Control system commissioning and startup of power recovery train (steam turbine, expander) for FCCU

Plant type
Refinery

Platforms
Surge detection in Rockwell Allen-Bradley ControlLogixBraun TUR-safe E16E368 TMR overspeed protection system for expander and steam turbineBently Nevada 3500 vibration monitoring system

Vietnam - Refinery

Project description
Control and protection system commissioning and startup of six steam turbines, driving water pumps

Plant type
Refinery

Platforms
Woodward Peak 150 steam turbine control, Woodward Protech GII overspeed protection

Finland - Power plant

Project description
Compressor control system upgrade for two instrument air compressors in parallel

Plant type
Power plant

Platforms
CC Compressor ACA Antisurge Control Application and Station Load-balancing application (SCA) on Valmet DNA DCS platform

Kazakhstan - Power plant

Project description
Commissioning and startup of one 32MW steam turbine generator set. Operator training and SAT procedures

Plant type
Power plant

Platforms
GE Fanuc 90-70 PLC, Proficy and Cimplicity HMI

Algeria - Compressor station

Project description
Retrofit of compressor control system including engineering design, programming and installation of new control system, for three compressors operating in parallel.

Plant type
Compressor station

Platforms
CC ACA Antisurge Control Application, PCA Performance Control Application en SCA Station Control Application on ABB AC800M

Norway - Nitric Acid Plant

Project description
Design, engineering, supply and commissioning and startup of control systems for one air compressor, one NOx compressor, including compressor and expander efficiency calculations, performance deviation and monitoring and transmitter replacement

Plant type
Nitric Acid Plant

Platforms
CC Compressor ACA Antisurge Control Applications on redundant Rockwell Allen-Bradley ControlLogix PLC, control cabinet, operator/engineering station with Iconics HMI software, transmitters and galvanic converters

Saudi Arabia - Chemical Plant

Project description
Control and protection system commissioning and startup of two (of six) steam turbines, driving pumps and compressors

Plant type
Chemical Plant

Platforms
Trisen TS310SV steam turbine control, Trisen Turbosentry overspeed protection, Siemens S7-200

Austria - Incinerator plant

Project description
Commissioning and startup assistance for steam turbine generator set after overhaul

Plant type
Incinerator plant

Platforms
Turbolog ETS-301/2/4 for overspeed protection and speed control

Colombia - Nitric Acid plants

Project description
Design, engineering, supply, and startup of CCS control system with Antisurge Control Application (ACA) including control cabinet, redundant Allen Bradley – ControLogix PLC, back-flow detector, galvanic converters, transmitters, engineering/operator station (HMI). The project also includes Expander and compressor efficiency calculation and monitoring, transmitter replacement

Plant type
Nitric Acid plants

Platforms
Control-Care ("CC") solution for compressor antisurge control and expander control on Rockwell Allen-Bradley ControlLogix

Norway - Offshore platform

Project description
Project management, design, engineering, supply, commissioning and startup of control system retrofit for one motor driven one-stage reinjection compressor and one motor driven three-stage re-compressor

Plant type
Offshore platform

Platforms
Control-Care ("CC") solution for compressor antisurge control on Rockwell Allen-Bradley ControlLogix, CC HMI for antisurge control on Emerson DeltaV DCS

United Arab Emirates - Gas Compression Station

Project description
Commissioning and startup assistance for three motor driven variable speed 2-stage compressors with parallel loadsharing for the Babgas Project

Plant type
Gas Compression Station

Platforms
Siemens PCS7, Bently Nevada 3500

Malaysia - Synthesis Plant

Project description
Design, engineering, procurement, construction and management for replacement of various control systems, machine monitoring and protection systems and other systems and instrumentation for two steam turbine compressor trains, one steam turbine generator and one steam turbine water pump

Plant type
Synthesis Plant

Platforms
Woodward Micronet Plus (redundant), Yokogawa Centum DCS, Bently Nevada System 1, Bently Nevada 3500, Woodward 505E speed control, Woodward Protech overspeed  protection, Woodward  Protech GII overspeed protection, PGPL Mechanic Actuator, Voith 2o3 Trip Block, Honeywell IPS

Angola - FPSO

Project description
Control system commissioning assistance on three gas turbine driven three-stage gas injection compressors

Plant type
FPSO

Platforms
Siemens PCS7

Australia - LNG Plant

Project description
Control system commissioning and startup of eight motor driven multistage compressor trains, including antisurge and performance and loadsharing control for QCLNG Project

Plant type
LNG Plant

Platforms
Rockwell Allen-Bradley ControlLogix with FactoryTalk HMI, Bently Nevada 3500

Finland - Chemical Plant

Project description
Control system upgrade for two motor driven process air compressors, including antisurge control, performance control and loadbalancing control

Plant type
Chemical Plant

Platforms
Control-Care Systems' ("CCS") Solution on ValmetDNA DCS. Compressor Antisurge Control, Compressor Performance Control, Compressor Loadbalancing Control

Spain - Power Plant

Project description
Troubleshooting and maintenance activities on steam turbine control and protection systems in power generation application

Plant type
Power Plant

Platforms
Rockwell Allen-Bradley PLC5, Woodward 505 steam turbine speed control

Italy - Fertilizer Plant

Project description
Installation, commissioning and startup surpervision for steam turbine speed control and overspeed protection systems and instrumentation

Plant type
Fertilizer Plant

Platforms
CCC Vantage GP speed control, CCC Guardian overspeed protection

Germany - Chemical Plant

Project description
Control system commissioning and startup of compressor train for Luhyclo Project

Plant type
Chemical Plant

Platforms
Siemens PCS7, Bruel & Kjaer vibration monitoring system

Australia - Gas Plant

Project description
Upgraded control system commissioning and surgetesting for two compressor trains

Plant type
Gas Plant

Platforms
Allen-Bradley Clx, Indusoft HMI

China - Air Separation Plant

Project description
Commissioning of an Air MAN Train consisting of a steam turbine driving a main air compressor and a booster air compressor for Kaiyangair project

Plant type
Air Separation Plant

Platforms
Siemens PCS7 based on S7-400 with ET200 Failsafe module Bently Nevada 3500 vibration monitoring. Brown Overspeed Protection. Tricon Triconex TMR ITCC System

Peru - Gas Compression Station

Project description
Control system commissioning and startup of two SGT700 gas turbine driven compressor trains, including process control

Plant type
Gas Compression Station

Platforms
Siemens PCS7

China - Air Separation Plant

Project description
Control system commissioning assistance for a steam turbine driven main air compressor and a booster air compressor train for Erdosair Project

Plant type
Air Separation Plant

Platforms
Siemens PCS7 based onS7-400 with ET200 Failsafe moduleBentley Nevada 3500 vibration monitoringBrown Overspeed ProtectionTricon Triconex TMR ITCC System

India - Steel Plant

Project description
Control system commissioning and startup of a electrical motor driven multistage refrigeration compressor train

Plant type
Steel Plant

Platforms
Siemens PCS7 Bently Nevada 3500

United Kingdom - Offshore platform

Project description
Control system commissioning and startup of 2 gas turbine driven compressor trains

Plant type
Offshore platform

Platforms
Siemens S7 (SCAUT) Bently Nevada 3500

Romania - Refinery

Project description
Project management and engineering of control system retrofit for a motor driven two-stage wet gas compressor including Emerson control system and transmitter buy outs

Plant type
Refinery

Platforms
Control-Care compressor antisurge control and performance control application on Emerson DeltaV

China - Power Plant

Project description
Control system design and engineering for a total of twenty three-shaft gas turbine generator systems

Plant type
Power Plant

Platforms
Siemens S7-400
WinCC

Angola - FPSO

Project description
Commissioning and start-up of three LM2500+ gas turbine generator sets

Plant type
FPSO

Platforms
Woodward Micronet Plus
Bently Nevada 3500
Envision HMI

Italy - Refinery

Project description
Commissioning of antisurge control system for two compressors

Plant type
Refinery

Platforms
Modicon Quantum PLC

Malaysia - Synthesis Plant

Project description
Basic design and engineering for rejuvenation of various control, monitoring and protection systems for two steam turbine compressors, one steam turbine generator and one steam turbine water pump

Plant type
Synthesis Plant

Platforms
Woodward Micronet Plus (redundant)
Yokogawa Centum
Bently Nevada System 1
Bently Nevada 3500
Woodward 505E speed control
Woodward Protech overspeed protection
Woodward  Protech GII overspeed protection

Kazakhstan - Refinery Sulphur Recovery Plant

Project description
Control system commissioning for two parallel trains of three combustion air blowers, including antisurge control, parallel loadsharing control and vibration monitoring

Plant type
Refinery Sulphur Recovery Plant

Platforms
CCC Series 5 Vanguard
Bently Nevada 3500
Bently Nevada System 1

Australia - FPSO

Project description
Commissioning and startup of two lift gas, two export gas and two flash gas compressor trains for CWLH Redevelopment Project

Plant type
FPSO

Platforms
Siemens S7‑400 redundant fail‑safe, WinCC
CCC S3+ antisurge
Bently Nevada 3500 vibration
Bently Nevada 3500 overspeed
Bently Nevada System1

Oman

Project description
FAT and commissioning supervision of an expander compressor for Saih Nihayada Depletion Compression (SNDC1) Project

Platforms
Yokogawa DCS
S2M E300 Automatic Magnetic Bearings
CCC S5 Reliant Redundant Antisurge

Romania - Refinery

Project description
Project management and engineering of control system retrofit for steam turbine driven hydrogen compressor

Plant type
Refinery

Platforms
CCS Compressor Surge Prevention Control,  CCS Compressor Performance Control, CCS Steam Turbine Speed Control on Allen-Bradley CLx, Woodward Protech GII Electronic Overspeed Protection

Italy - Power Plant

Project description
Reliability run for two GE LM6000 gas turbine generator sets

Plant type
Power Plant

Platforms
Woodward Micronet Plus

Russia - Offshore platform

Project description
On site control system troubleshooting of three LM2500 gas turbine generator sets

Plant type
Offshore platform

Platforms
Atlas Fuel Control
Siemens PCS7 Sequencer

Qatar - Chemical Plant

Project description
Troubleshooting and tuning of antisurge control system for electrical motor driven six-stage propane compressor

Plant type
Chemical Plant

Platforms
Schneider Elecric Modicon PLC

United Arab Emirates - Gas Plant

Project description
Commissioning and startup for three different compressor stations, each with three electrical motor driven two-stage compressors with parallel loadsharing

Plant type
Gas Plant

Platforms
Siemens PCS7
Bently Nevada 3500

United Kingdom - FPSO

Project description
Commissioning of two Solar gas turbine driven Datum D-08 compressors

Plant type
FPSO

Platforms
Allen-Bradley CLx

Tindouf, Algeria - Power Plant

Project description
Site supervision for commissioning and startup of two GE TM2500+ gas turbine generator packages

Plant type
Power Plant

Platforms
Woodward Micronet Plus

Béni Abbès, Algeria - Power Plant

Project description
Site supervision for commissioning and startup of two GE TM2500+ gas turbine generator packages

Plant type
Power Plant

Platforms
Woodward Micronet Plus

Tammanrasset, Algeria - Power Plant

Project description
Site supervision for commissioning and startup of two GE TM2500+ gas turbine generator packages

Plant type
Power Plant

Platforms
Woodward Micronet Plus

Netherlands - Offshore platform

Project description
Control system panel design, engineering and installation of two PGT16 turbines

Plant type
Offshore platform

Platforms
Woodward Micronet Plus

United Kingdom - Underground Gas Storage

Project description
Commissioning of an HOFIM (high speed oil free integrated motor) compressor for the Hole House Gas Storage Project

Plant type
Underground Gas Storage

Platforms
Siemens S7-400 Failsafe
WinCC

Finland - Nitric Acid Plant

Project description
Commissioning and startup of an antisurge control system for two axial air compressors

Plant type
Nitric Acid Plant

Platforms
CCS antisurge control on
Rockwell Allen-Bradley ControlLogix with
Iconics Genesis 32 HMI

Germany - Underground Gas Storage

Project description
Commissioning of two HOFIM (high speed oil free integrated motor) compressors in parallel and serial loadsharing

Plant type
Underground Gas Storage

Platforms
Siemens S7-400 Failsafe
WinCC

Brazil - Refinery

Project description
Commissioning and start-up of a steam turbine driven H2 recycle compressor train at Petrobras Refinaria Landulpho Alves (RLAM)

Plant type
Refinery

Platforms
Triconex Trident Steam Turbine and Compressor Controls
CCC S5 Reliant Antisurge Control
CCC S5 Guardian Overspeed Protection
CCC TrainView and Elliott local HMI's
Bently Nevada 3500 Vibration Monitoring

Nigeria - Offshore FPSO

Project description
Field engineering services for control system check-out and commissioning of two VRU, two OH and two LP screw compressors.
Consultancy in LO and SO contamination issues. General turbomachinery controls assistance on installed base

Plant type
Offshore FPSO

Platforms
Yokogawa DCS
Bently Nevada 3500
Bently Nevada System1
CCC S5 Vanguard
Woodward fuel gas valves

Egypt - Polypropylene Plant

Project description
Field services on instrumentation and controls regarding the commissioning of a turbo expander generator unit

Plant type
Polypropylene Plant

Platforms
Bently Nevada 3500
Woodward Protech

Netherlands - Anna Paulowna BBL4 gas plant

Project description
Field supervising services for testing of sequencing, logic, C&E, all instrumentation loops and interfacing with third party systems on electric motor driven gas mixing and export compressor

Plant type
Anna Paulowna BBL4 gas plant

Platforms
ABB 800m PLC
CCC S5 Reliant

United Arab Emirates - Gas Plant

Project description
Operator and maintenance training services on compressor controls for Babgas Compression Project

Plant type
Gas Plant

Platforms
Siemens PCS7
Bently Nevada 3500

Algeria - Gas Plant

Project description
Field engineering services on control system commissioning (including F&G) of a variable speed electric motor driven gas export compressor

Plant type
Gas Plant

Platforms
Siemens S7-400 redundant
Bently Nevada 3500
CCC S3++

Denmark - Offshore Production Platform

Project description
Field service assistance for program modifications to include additional trip functionality and curves due to LP compressor re-bundling and upgrading of master/slave LP/HP HMI systems

Plant type
Offshore Production Platform

Platforms
Allen-Bradley PLC5
Factory Link HMI

Saudi Arabia - Cement Factory

Project description
Field assistance for re-engineering and start-up of ABB BCC gas turbine generator application

Plant type
Cement Factory

Platforms
Allen-Bradley CLx
Allen-Bradley XM-220 overspeed device
ABB Synchrotact1
ABB AVR

Singapore - FPSO

Project description
Commissioning and start-up of three LM2500+ gas turbine generator sets

Plant type
FPSO

Platforms
Woodward Micronet Plus
Bently Nevada 3500
Envision HMI

Mexico - Refinery

Project description
Field engineering services for commissioning of the controls systems on a steam turbine driven H2 recycle compressor system

Plant type
Refinery

Platforms
Allen-Bradley CLx
Factory Link
Bently Nevada 3500 vibration
Bently Nevada 3550 overspeed

Mozambique - Gas Transportation Station
Ref#04-KZ-Offshore

Project description
Field engineering services for commissioning of gas dehydration and glycol regeneration package

Plant type
Gas Transportation Station

Platforms
Rosemount instrumentation
Emerson Delta V DCS
HIMA ESD system

Russia - Oil Production Platform

Project description
Field service assistance on the commissioning of two LP electric motor driven and two HP gas turbine driven injection compressors

Plant type
Oil Production Platform

Platforms
Allen-Bradley CLx
Envision HMI

South Africa - Platinum Mine

Project description
Engineering consultancy and commissioning of two electrical motor driven process air blowers, running in parallel

Plant type
Platinum Mine

Platforms
CCC S3++
Bently Nevada 3500
Allen-Bradley CLx

Singapore - FPSO

Project description
Field engineering services for precommissioning and running tests of three gas turbine driven generator sets of 30MW each

Plant type
FPSO

Platforms
Woodward Micronet
Bently Nevada 3500
Envision HMI

Kazakhstan - Offshore Platform
Ref#04-KZ-Offshore

Project description
Long term service agreement (LTSA) support for control and protection systems on critical rotating equipment, including multiple flash gas compressors, and raw gas injection compressors

Plant type
Offshore Platform

Platforms
CCC Series 5 compressor antisurge and loadsharing control
CCC Traintools
GE Bently Nevada vibration monitoring systems