THE SCENARIO

• Client has highly varying flow requirement of Nitrogen at @ 30-32 bar pressure in their process. The flow varies from 25% to 100% and yet did not want any stoppages in their process with a possibility of going up to 130% as well at times.
• After discussion with the Compressor OEM, they decided to purchase 3 compressors of equal capacity.
• The compressors will be started, stopped, loaded and unloaded as per the process flow requirement.
• To have more flexibility for future modifications, the client requested to have a PLC based control for the Compressor rather than an OEM standard controller.
• Criticality of the process in the plant demanded a separate control system for each compressor to avoid any plant stoppages arising out of non availability of the control system.
• The client requested for a SCADA system common between the 3 Compressor Controls and placed in the client’s DCS room. They also requested for a common HMI operable from near the compressor for operator convenience.

THE OUTCOME

All the three compressors were commissioned with the only operator input required being the start button.

The complete start up, stop, loading and unloading of the compressor was automated and presented to the client without glitches.

All compressors shared the load equally all through out the 72 hour run maintaining the process flow to the client’s satisfaction.

A great hand over work by our team members to the client with necessary trainings and briefings for their further operation without any further assistance required from our engineers.