- Project: NGL Expansin - Ingeniera Bsica & Detalle

CUARTA BOMBAJOB N: 2TC.0133-0001

EQUIP.:
TAG N:

P-5101D P-5201D

P-5301D P-5401D

DWG/DOC. N: 3149-M-SP-510-032
PO N: 09AE0028-31
MR N: 3149-M-MR-000001

REV.

DATE

16-06-10

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UPDATE ECU-ESM VALUES pgs 8, 10 and 11

D.N.

D.Q.

D.Q.

16-06-2010

GENERAL REVISION

D.N.

D.Q.

D.Q.

11-05-2010

GENERAL REVISION

D.N.

D.Q.

D.Q.

12-04-2010

GENERAL REVISION

A.P.

D.Q.

D.Q.

31-03-2010

GENERAL REVISION

A.P.

D.Q.

D.Q.

04-03-2010

ADD COMMENTS

A.P.

D.Q.

D.Q.

10-02-2010

FOR APPROVAL

A.M.

D.Q.

D.Q.

05-11-09

REVISION

DESCRIPTION

BY

VER

APPR

DATE

ORIGINAL:

BY:

CUSTOMER/PROJECT:

TECHINT

VER:

APPR:

DATE:

TYPE

AEM:

CUSTOMER'S REFERENCES:

IDP REFERENCES:

NATURAL GAS/NGL SYSTEM

EQUIP:4x10 DA
RR: ---

CAMISEA

TAG: P-5101/5201/5301/5401 D
TITLE:

Control Philosophy Description

Drawn No.:
CPDSSD09AE0028

REV.

SHEET:

01-11

This document is property of Flowserve Pumps Argentina S.A. It must not be copied or used without authorization

Page 11 of 11

CONTROL PHILOSOPHY
A) GENERAL
This document describes the control philosophy of the Entire Pumping Unit. The Control System
used will be unique and placed in the Local Control Panel (LCP) near to the main equipment and it will
have an operation panel (panel view 1000-Allen Bradley) available for consulting the data
controlled by the same equipment. As its main characteristic the equipment itself will be suitable to
operate in stand-alone mode. The LCP will have a selector switch (Local-0-Remote) that allows the
equipment to be operated from PLC Station. From there it can be started up and stopped both in
normal position and in emergency position. Also from this place the speed of working and
communication from the Control Net module among PLC are controlled. It allows knowing the status of
all the system variables that are being read by PLC of the LCP. The LCP will have a Nema 4X
enclosure built in 2mm thick stainless steel plate AISI 304.
The LCP will be thermally conditioned to perform in the range requested by Allen Bradley (0-60C).
When the temperature is lower than 5 C, the LCP will be heated by self-regulated E-Tracing (120
VAC shall be supplied by client), this installation will be CL1 DIV1 group C and D T3. The required
power is approximately 200 watt and should be supplied permanently. The required power from the
external box CL1 DIV1 group C and D T3 attached at the LCP will be supplied.
The 120 VAC needed to supply PLC-Engine must be from UPS (wired by Techint).
All the elements installed inside of LCP shall be CL1 DIV2 Group C and D T3. The LCP box will be
hermetically closed.
BEFORE FIRST START UP
Before the first start up, a Pre-commissioning, start up Check List and a Control Report will be
done.
OPERATION OF MOTORS, HEATERS, E-TRACING OF THE GROUP
The functioning is similar in all cases.
The PLC program will detect if it is necessary to power or not the different loads.
1-

Output 460 VAC Gear

a. Lube Oil Heat-Exchanger Gear (fan):

When the temperature is higher than a pre

set value the corresponding relay (K7) will be closed through OB32 module output
(DO1-6+)
b. Lube Oil Auxiliary Pump Gear:

When the pressure is lower than the set value the

corresponding relay (K6) will be closed through OB32 output (DO1-5+)

c. Lube Oil Heater Gear:

When the temperature is lower than the indicated value

the corresponding relay (K8) will be closed through OB32 output (DO1-7+)
2- Output 120 VAC Heater
a. Thrust Bearing Pump Heater:

When the temperature is lower than a pre set value

the corresponding relay (K9) will be closed through OB32 output (DO1-8+).
b. Radial Bearing Pump Heater:

When the temperature is lower than a pre set

value the corresponding relay (K10) will be closed through OB32 output (DO1-9+).
c. Tracer LCP:

When the environment temperature is lower than 5C Tracer LCP

will operate.

In JB-XX101 there are 2 pilot lights, one of them indicates that

command 120VAC Tracing is powered and the other one indicates that Tracer is in
service. The operation is automatic (the PLC of the LPC does not operate) by
means of an adjustable thermostat that is located in the JB-XX101, and is sensed
by a 1,20mts capillary tube located in the LCP.
3-

The following loads are permanently powered from MCC:

a- Engine Pre Lube Motor in 120VCA, 60Hz, 1Ph.
b- Engine Lube Oil Heater in 480VCA, 60Hz, 3Ph.
c- Engine Water Heater in 480VCA, 60Hz, 3Ph.
d- Tracing LCP in 120VCA, 60Hz, 1Ph.

START AND NORMAL STOP, AND EMERGENCY STOP (EMSS)

The doors have padlocks. Only an authorized operator must open them
1) Switch Selector in position 0: In this position, the start up can not be done. Before the first start
with the switch in this position, the LCP, Power Supplies, PLC and the different consumption
points of the Engine will be powered. As ESM-ECU indicates ready state and temperature of
Pump bearings (End/Coupling sides) are permissive to start up, it will not be possible to start
until the minimum oil pressure and minimum bearing temperature are reached. Then the
system verifies if the trip signal is actuated. When it is true the engine start is locked and the reset
button must be pushed. When it is pushed, a verification sequence is run and after checking
that all conditions are fulfilled the Panel View will show Ready for Start.
2)

Switch Selector in LOCAL position: This switch has two contact blocks, one of them goes
directly to the entrance of the PLC(DI1-15+) in a permanent way and the motor can be started
only in LOCAL position. This will be indicated in the PLC. The other contact is connected to
momentary Local start button placed in the door of LCP. As the contact is normally open, when
the button is pressed it will send a positive pulse to other digital input of PLC. This is a mechanical
interlock that

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obligates to start only through the selected circuit. In this position it is possible to stop the
equipment without inconvenient even with the selector switch in Remote position. The stop is
produced closing the valve commanded by ESM(ECU). When this is stopped the Engine will be
operative waiting for a new start order. In local mode the speed control must be done from the
Panel View in the PLC.
3)

Switch Selector in REMOTE position: This switch has two contact blocks, one of this goes
directly to the entrance of PLC(DI1-17+) in a permanent way and the motor can be started
only in REMOTE position. This will be indicated in the PLC. The other contact is connected to a
Remote relay placed in the PLC Station. In this position

it is possible to stop the

equipment without inconvenient even with the selector switch in Local position. The stop is
produced closing the valve commanded by ESM(ECU). When this is stopped the Engine will be
operative waiting for a new start order.
4) Operation of EMSS: The Waukesha engine has emergency push buttons that transmit the signal
to the ESM(ECU), and from this one to the LCP to be indicated (DI1-7+). The Engine has its own
emergency stop system through two buttons placed on the right and on the left side of engine.
When one of these is pressed, it will report the situation to PLC. The EMSS can also be operated
from the LCP(DI1-18+) or the PLC STATION(DI1-24+),

in this case it consists of a series of

normally closed contacts. Any of these stops cause the shut-down of the engine through the digital
output (DO1-24+). This operation implies the closing of the GSV valve, closing the gas inlet
completely. Functionality is operated from the GSV closing the entrance of gas completely.
5)

When the equipment starts with the selector switch in Local or Remote position it is possible to
change operative mode for a new start in Remote or Local position without stopping

the

equipment. When changing from Remote to Local or vice versa the selector switch has to pass
to position 0 for a while before going on to the next mode (REMOTE or LOCAL). If this
transference is done in a lower time interval than a previously set one, the operative mode for a
new start will be changed. If time is > 20 seconds the pump will stop in a normal way.
6) When then equipment is started, the indication In Start is visualized en Panel View while the prelubrication is running. When the equipment is running, the indication in panel view is RUN
CONTROL SYSTEM
See set values in documents CEM09AE0028 and INLIST09AE0028
All the signals controlled by PLC cause the following effects:
A) PUMP
1. Thrust bearing temperature: Single RTD. When temperature goes up to the set value,
RTD acts inducing alarm or trip. RTD has no inhibition period. In case of trip, it does
not

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allow to start up the unit until the temperature goes down to the required value. In case
of burn-out, a trip signal will be emitted.
2. NDE Bearing vibration: Analog sensor 4-20 mA: It is inhibited during start up operation
for an adjustable period of time, the time period can be changed from the panel view.
The set up time in this particular case will be 4 minutes. (to be programmed by
Flowserve). Function: Alarm and Trip.
3. NDE Radial Bearing temperature: Double RTD: One active, one spare. It will sense
radial bearing housing temperature. Below 18 C do not permit the Pump Unit start up,
when the temperature increase up to 85 C it emits an alarm signal and with more than
90 C emits a trip signal.

It also will command the E-Heater, H-XX183 (see

FLCD09AE0028).
The E Heater works in the following situation: Low set value start (23 C). High set
value stop (40 C).
4. NDE Mechanical Seal Reservoir low level switch Ultrasonic level switch sensor. It will
sense low level in reservoir. When minimum level is reached, sensor emits an alarm
signal.
5. NDE Mechanical Seal Reservoir high pressure. High pressure switch. It will sense
reservoir internal pressure (normally atmospheric pressure) and when it goes up,
pressure switch emits a trip signal. (primary seal broken)
6. Pump Low suction pressure. Analog sensor 4-20 mA. Before equipment operation,
if the sensor detects low pressure, it inhibits the pump to start. During normal function,
in case of low pressure, pump stop will be produced after a temporization (value
feasible of edition) in order to prevent short duration pressure variation that can
interfere normal functioning of the equipment during admission period. The values of
alarm and trips depend on each station.
7. Pump High discharge pressure Analog sensor 4-20 mA: the trip is inhibited during start
up period, settable from panel view, during this period the pump will not be stopped
due to high or low discharge pressure. In normal functioning, the sensor has no
inhibition period and it provokes trip whenever the set point value is exceeded. The
discharge pressure must not be higher than the designed piping pressure. The values
of alarm and trips depend on each station.
8. Pump case temperature: Double RTD: one active, one spare. It has no inhibition period.
In case of trip, it does not allow to start up the unit until the temperature goes down to
set values. In case of very high temperature or burn-out, a trip signal will be emitted.

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9. DE Radial Bearing. Double RTD: One active, one spare. It will sense radial bearing
housing temperature. Below 18 C do not permit the Pump Unit start up, when the
temperature increase up to 85 C it emits an alarm signal and with more than 90 C
emits a trip signal.

It also will command

the E-Heater,

H-XX184.

(see

FLCD09AE0028).
The E Heater works in the following situation: Low set value start (23 C). High set
value stop (40 C).
10. DE Bearing vibration, Analog sensor 4-20 mA: It is inhibited during start up operation
for an adjustable period of time, time period can be changed from the panel view. This
period that can be changed through panel view values edition. The set up time in this
particular case will be 4 minutes. (to be programmed by Flowserve). Function: Alarm
and Trip.
11. DE Mechanical Seal Reservoir high pressure. High pressure switch. It will sense
reservoir internal pressure (normally atmospheric pressure) and when it goes up, the
pressure switch emits a trip signal. (primary seal broken)
12. DE Mechanical Seal Reservoir low level. Ultrasonic level switch sensor. It will sense
low level in the reservoir. When minimum level is reached, the sensor emits an alarm
signal.

B) GEAR

15. Low speed thrust bearing temperature (inactive side). A Single RTD, Function: Alarm
and Trip, In case of trip, it does not allow to start up the unit until the temperature goes
down to the required value. In case of very high temperature or burn-out, a trip signal
will be emitted.
16. Low speed thrust bearing temperature (active side), Function: Alarm and Trip.: A
Single RTD. It is furnished in thrust bearing. RTD has no inhibition period. In case of
trip it does not allow to start up the unit until the temperature goes down to the
required value. During test, a normalized rheostat will be used in order to verify this
protection. In case of very high temperature or burn-out, a trip signal will be emitted.
17. Low speed radial bearing temperature. Double RTD, Function: Alarm and Trip.: One
active, one spare. It will sense radial bearing temperature. RTD has no inhibition
period. In case of trip, it does not allow to start up the unit until the temperature goes
down to the required value. In case of very high temperature or burn-out, a trip signal
will be emitted.

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18. Low speed radial bearing temperature (engine side). Double RTD, Function: Alarm
and Trip. : One active, one spare. It will sense radial bearing temperature, and it will
not allow to start up the unit when temperature is over allowable limits. In case of very
high temperature or burn-out, a trip signal will be emitted.
19. High speed radial bearing temperature (engine side). Double RTD, Function: Alarm
and Trip. : One active, one spare. It will sense radial bearing temperature, and it will
not allow the unit to start when temperature is over allowable limits. In case of very
high temperature or burn-out, a trip signal will be emitted.
20. High speed radial bearing temperature (engine side). Double RTD, Function: Alarm
and Trip: One active, one spare. It will sense radial bearing temperature, and it will not
allow the unit to start when temperature is over allowable limits. In case of very high
temperature or burn-out, a trip signal will be emitted.
21. NDE high speed bearing vibration: Analog sensor 4-20 mA, Function: Alarm and Trip:
It is inhibited during start up operation for an adjustable period of time, time period can
be changed from the panel view. The set up time in this particular case will be 4
minutes.
22. DE high speed bearing vibration: Analog sensor 4-20 mA, Function: Alarm and Trip: It
is inhibited during start up operation for an adjustable period of time, time period that
can be changed from the panel view that in this particular case will be 4 minutes.
23. Lube oil filters differential pressure. Sensor transmitter 4-20 mA. It will sense
differential pressure of oil filters. Alarm function.
24. Gearbox Low level oil. Sensor Level ultrasonic switch. It will sense low level in
gearbox. When minimum level is reached, the sensor emits a trip signal.
25. Header lube oil temperature

control. Sensor

transmitter

4-20mA.

It senses

temperature of oil in the gearbox. When the temperature descends from 32 C the
heater H-XX192, turns on, and when the temperature ascends up to 40 C the heater
turns off. When the temperature ascends up to the 53 C the heat exchanger fan turns
on, previously the thermostatic valve must open automatically. The fan will be
disconnected when the temperature descends from 43 C. The thermostatic valve
must close automatically at 40 C.
26. Header low lube oil pressure control. Sensor pressure switch. It senses pressure of oil
lubrication piping in gear box. When the pressure goes down below the set value (1,3
bar), the sensor will turn on the auxiliary mechanical oil pump with 10 seconds delay.
27. Header lube oil pressure control. Sensor transmitter 4-20mA. It senses the gearbox
bearings lubrication piping lube oil pressure in gear box. When the pressure goes

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below the set value (0,5 bar), the sensor will emit a trip signal (9 seconds delay). If the
pressure goes over the set value (3,0 bar), it turns off the auxiliary electrical oil pump
and the system is lubricated by mechanical oil pump. If the pressure goes over 3 bar,
the alarm function will be actuated by communication and in panel view (9 seconds
delay).
The sensor is inhibited during start up by means of a temporizer (60 seconds).
C) ENGINE
28. Over Crank. When the Unit is ready for start and the push button (DO1-0+) of the PLC is
actuated (in local or remote) the ASV solenoid valve will open from the ECU-ESM and
the Engine will start. If the engine is cranked longer than the 30sec., the starting
attempt is terminated, the ignition and fuel are stopped, and the starter motor is-deenergized.
29. Engine Vibration: Analog sensor 4-20mA: It is inhibited during start up operation for a
period adjustable between 2 and 10 minutes, time period can be changed from the
panel view. In this particular case the interval will be 4 minutes. In case oh high vibration
an alarm will be issued and if the problem persists in case of high-high vibration the
pump will be tripped. See with Waukesha
30. Engine Actuator. The Engine actuator actuates the shutter closing or opening it slowly,
and regulates the amount of fuel into carburetor. The Air/Fuel ratio Control (AFR208)
regulates the mix of fuel/air of engine. The speed regulation of the equipment is
controlled by the PLC station, through the AI2-0+ input 4-20mA and the AO1-0+ output
of the PLC of the LCP to the ECU-ESM, and from this one to the ITC (Integrated
Throttled Control).
31. Engine header lube oil pressure control. Sensor transmitter 0.5-4.5Vdc. It senses
pressure of engine-lube-oil in the ECU-ESM. When main pump turns off, the auxiliary edriven oil pump will turn on. The low engine lube oil pressure inhibits main pump starts.
It emits either a trip or an alarm signal through the panel view of the engine located in
the LCP.
32. Engine header lube oil temperature. Sensor Thermocouple. It senses engine oil
lubrication temperature in the ECU-ESM. It emits either a trip or an alarm signal. In case
of burn-out, a trip signal will be emitted through the panel view of the engine located in
the LCP.
33.

Remote speed engine RPM selector (ESM-ECU) is commanded by contact REMXX145 (DO1-1+ from PLC-LCP to ESM-ECU). This field signals when the remote rpm

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selector is ON or OFF. When the output is high (8.6 36 volts), remote rpm selector is
active. When remote rpm engine selector is ON, engine speed is based on analog
output OFG-XX129 (AO1-0+ (4-20 mA)) from PLC-LCP to ESM-ECU. When remote
rpm engine selector is OFF, engine speed is based on Idle IDL-XX156 (DO1-18+)
and High Idle RPM or Low Idle RPM. Idle indicates whether Low Idle RPM (if
Idle is low) or High Idle RPM (if Idle is high) is active. The values of High Idle RPM
and Low Idle RPM will be entered in ESM on PanelView of Waukesha. This must be
confirmed by Waukesha.
34. Engine intake manifold temperature (left bank). Sensor Thermocouple. It senses
Engine intake manifold temperature in the ECU-ESM. It emits either a trip or an alarm
signal. In case of burn-out, a trip signal will be emitted through the panel view of the
engine located in the LCP.
35.

Engine detonation. Sensor: Switch. It senses engine detonation in the ECU-ESM and
emits an alarm and a trip signal when detonation goes over determined values through
the panel view of the engine located in the LCP. See with Waukesha.

36.

Engines

exhaust temperature

(right bank). Sensor Thermocouple.

It senses

Engine right side manifold exhaust temperature. an alarm signal.

37. Engine exhaust temperature (left bank). Sensor Thermocouple. It senses Engine left
side manifold exhaust temperature. It emits an alarm signal
38.

Engine inlet pressure low gas fuel control. Sensor transmitter. It will sense Engine inlet
gas pressure and when it goes below the set value, it emits an Alarm and trip signal. It
is permissive of starting up in case the pressure is not adequate.

39. Engine jacket water temperature. Sensor Thermocouple. It senses engine jacket water
temperature in the ECU-ESM. It emits a trip or an alarm signal. In case of burn-out, a
trip signal will be emitted through the panel view of the engine located in the LCP.
40.

Engine jacket water low level. Sensor Level switch. It will sense level of engine jacket
water (in radiator). When minimum level is reached, the sensor emits an alarm signal.

41.

Engine after cooler water low level. Sensor Level switch. It will sense level of
engine after cooler water (in radiator) when minimum level is reached, the sensor
emits an alarm signal.

42. Gas Inlet valve (main). MGV valve is ON-OFF. This valve is commanded by GSV
solenoid, by the ECU-ESM. The MGV works normally open (energized). In case of trip
(shutdown), GSV closes the MGV (des-energized). If the stop is normal stop, the GSV
remain energized.

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43. Peco filter differential pressure. Sensor transmitter 4-20 mA. It will sense differential
pressure of Peco (gas filter separator). Only for alarm purposes.
44. EMSS. Discrete Signal. It indicates that the motor was stopped by the motor itself,
indicated in (DI1-7+)
45. Speed Control from LCP Station and PLC by the ECU-ESM. Analogical signal 4-20mA.
OFG-XX129.
46. Engine low and Over Speed, RPM indicator, Horometer. Magnetic Pick-up N 1 emits a
signal received by the ECU-ESM.
47. Engine exhaust temperature (each of the 12 cylinder). Sensor Thermocouple. It emits
an alarm signal.
48. Engine, low oil level carter, to be indicated in (DI1-9+) of PLC-LCP. It emits an alarm signal.
49. Knock sensor. Uncontrollable knock will shut down the engine after a period time calibrated by
Waukesha Engine. A digital output from the ECU indicates that uncontrollable knock is occurring
so that the customer can initiate some knock reduction strategy such as reducing engine load.
To be indicated in (DI1-8+) of PLC-LCP. It emits an alarm signal.

50. Jacket water pressure. Low Jacket water pressure, to be sensed in (AI1-12+) of PLC-LCP.
It emits an alarm signal.
51. Air/Fuel ratio control Sensor. To be sense in ESM_ECU (the set values of alarm and trip
will be confirm by Waukesha).
52. Intake manifolds gas pressure sensors. Two analog sensor 0.5-4.5Vdc in right manifold
and one in left manifold (the set values of alarm and trip will be confirm by Waukesha)
D) Trips Signal Summary.
Its a Discrete Signal (DO1-23+), that is summary of all trip signals, including PLCs of the
LCP, fails and 24 VDC Power Suppliers failures.