HydroCOM
High energy savings and excellent controllability
For efficient capacity control
Many capacity control systems waste energy, are slow and inaccurate.
HydroCOM, however, achieves best results and pays for itself within a short period of time.
It saves money due to excellent controllability and by significantly improving performance.
Some questions you should ask yourself
about your existing control system:
Economical aspects
Automation requirements
Does my control system waste energy like
Can my control system be fully integrated
a bypass valve?
into the DCS to allow remote control
unlike pockets and manual operation?
Process issues
Does it provide any kind of self-diagnosis
Does my control system react quickly
functions?
enough and does it precisely control all
required pressure levels, flow rates or
Environmental restrictions
other parameters unlike step control or
Does my system help to fulfil stringent
bypass valves?
environmental conditions unlike
control-flares?
Control range
Does my control system have any
limitations with respect to molecular
weight, suction pressure, temperature,
minimum load, etc. as with speed control,
pockets, step control etc.?
A wise investment
HydroCOM is the smartest, most efficient, stepless,
highly dynamic and fully automated control system.
What makes HydroCOM the perfect
answer to your compressor control
system problems?
Highest energy savings
Fully automated system
HydroCOM follows an intelligent concept:
HydroCOM interfaces to a DCS or
just the required amount of gas needed is
a loop controller.
being compressed.
Monitoring
Stepless control range
Monitor and protect your compressor with
HydroCOM uses hydraulic actuation to
RecipCOM, our machinery protection and
use the full control range. HydroCOM
online monitoring system. RecipCOM
is independent of process variations
is certified according to IEC 61508 /
such as suction pressure, molecular
61511, API 670 and ANSI / ISA-84.
weight changes, temperatures, and other
condtions.
Proven success
HydroCOM is used in a variety of
Highest control dynamics
applications. Basically every reciprocating
HydroCOM is very fast and precise due to
compressor installation can be equipped
the quick response of the solenoid valve
with HydroCOM.
inside the actuator:
within 3 crank-shaft revolutions
load changes from 10 to 100% are
possible.
Smart actuators are at the heart of HydroCOM
The basic principle of HydroCOM:
the compression stroke.
With HydroCOM the suction valve is kept
open by the unloader so a certain amount
of gas is pushed back into the suction
chamber. Then, at precisely defined point
of time, the unloader is released and the
PD
D r,50
D
Pressure
Normally gas is being compressed during
C r,50
suction valve closes. Therefore only the
gas remaining in the cylinder is being
compressed.
PS
Energy Savings at
50% partial load
B
Volume
nn
Electric housing
oil-section of the valve housing and the
Microprocessors inside the electric
gas-section of the compressor.
housings handle the fast and precise
actuator timing. When installing the
actuator only power supply and bus
cables have to be electrically connected.
oo
Valve housing
The valve housing is the hydraulic heart
of the HydroCOM actuator. Oil pressure
A temperature sensor measures
continuously the valve cover temperature
and makes this value available for
indication in the process control system.
This temperature is used to monitor the
condition of the suction valve.
(connection on top) is applied to the
qq
HydroCOM unloader
hydraulic piston to push the unloader
The motion of the HydroCOM unloader
down when needed. The solenoid valve
is controlled by the hydraulic pressure
(similar to those in common rail diesel
applied in the valve housing.
injection systems) is the fast switching
element giving the HydroCOM its high
rr
Suction valve
dynamics.
The HOERBIGER plate or ring type
pp
Seal housing
The seal housing fits directly to the
suction valve cover. It separates the
suction valve with non-metallic sealing
elements ensures long life time and best
efficiency.
HydroCOM integrates seamlessly
Modular system design
HydroCOMs modular design makes integration straight forward for both existing and
new compressor installations. Process control tasks are implemented in a DCS or a loop
controller. In a control panel the HydroCOM compressor interface unit (CIU) carries out
data exchange between the DCS and HydroCOM.
Field
Switchroom
TDC
1994
4-20 mA
binary signal
or Modbus
IA
BUS
CIU
OIL
Compressor Condition Report
Unit Name:
Location:
RTC21000 - C
FLL
Load Step:
Percent Load:
Model:
Unit Mfr:
TCV10
DRESSER RAND
Date:
4/28/1994 [Link] AM
Serial No.:
3
86.4 %
UNIT COSTS
HSS
Fuel Cost:
Brake Power from the load:
Cost of Each BHP:
1673.37
3654.50
0.46
$/day
bhp
$/bhp-day
ENGINE COSTS
Percent of Fuel Cost
Actual Fuel Consumption:
Predicted Fuel Consumption:
Deviation From Predicted:
Cost of Deviation:
8675.17
7434.80
BTU/BHP - hr
BTU/BHP
- hr
7434.80
1240.36
239.26
7282.35
87388.25
BTU/BHP - hr
$/day
$/month
$/year
14.3
COMPRESSOR COST OF LOSSES
Total Losses
Valve and Passage Losses:
Pulsation Losses:
Gas Recirculation Losses:
397.38
153.18
0.78
Total Compressor Cost:
Hydraulic Unit
DCS / PLC
bhp
bhp
mmscfd
Estimated Cost of Losses
172.86
66.63
5.97
$/day
$/day
$/day
245.46
7471.32
89655.86
$/day
$/month
$/year
484.72
14753.67
177044.11
$/day
$/month
$/year
TOTAL DEVIATION FROM PREDICTED
Percent of Fuel Cost
10.3
4.0
0.4
%
%
%
14.7
Percent of Fuel Cost
29.0 %
1995
1996
1997
1998
1994
1995
1996
1997
1998
HydroCOMs many success stories
Many users worldwide take advantage of the outstanding performance of HydroCOM.
Nearly 600 HydroCOM installations are
achieving significant advantages over
other systems.
HydroCOM installations are found in
many industrial applications including:
Chemical plants
Refineries
Gas transport and storages
Chemical
Gas turbine plant
Refining
Natural gas
Gas turbine plants
HydroCOMs leading edge technology,
optimal integration and excellent
maintenance features have proven to be
the ideal choice for customized process
control systems.
Not only does HOERBIGER lead the way
in compressor controls, it also provide
local support from the largest service
network in the world.
Refining
The benefits of HydroCOM at a glance
Maximum energy savings
Suction valve temperature
Stepless control for excellent
monitoring on-board.
controllability
Full integration into plant control
Broad control range for process
system
flexibility and easy start/shutdown
Fast and precise: ideal for stable
Fully automatic for easy operation
Easy and quick upgrade /
dynamic control
integration, fits on most
compressors
HydroCOM Specifications
Control Range
10 - 100% *
Max. suction pressure
160 bar / 2320 psi
Max. suction valve temperature
120 C / 220 F
Max. compressor speed
1200 rpm
Corrosive Environments?
yes
Non-lubricated service?
yes
Suction valve
non-metallic plate or ring
Max. number of actuators
48
Ex certifications
EU (ATEX), US (FM), Canada (CSA), Japan
* Control range depends on the application
[Link]
The HOERBIGER Group
HOERBIGER Compression Technology is a business unit of HOERBIGER Holding AG, Zug /
Switzerland. HOERBIGER is active throughout the world as a leading player in the fields of
compression technology, automation technology and drive technology. In 2008, its 6,300
employees achieved sales of around 1 billion Euro. The focal points of its business activities
include key components and services for compressors, engines and turbomachines, hydraulic
systems and piezo technology for vehicles and machine tools, as well as components and
systems for shift and clutch operations in vehicle drive trains of all kinds. Through innovations
in attractive technological niche markets, the HOERBIGER Group sets standards and delivers
cutting-edge solutions for the benefit of its customers.
No additional space required
High standardisation of parts /
systems for high reliability and
cost effectiveness on spares
Optional upgrade to online
monitoring including pV, rider ring
wear and vibration monitoring
Proven at nearly 600 installations
