Presentation on Engine
Driven Residual Gas
Compressor
LPG plant Kwale. Delta state, Nigeria.
Objective
To familiarize & understand control philosophy of the machine in
simple terms.
To have knowledge sharing on problems faced & solutions.
Maintenance Practices deployed.
Brief Introduction..
We have 11 numbers of RGC machines. Out of which 4 are 2 stage
compressor and 7 are single stage compressor.
Engine & compressor have their own controller. (ESM / ESM-2 by
Waukesha for engine, DE-3000 by Altronics for compressor)
Compressor is controlled by DE-3000, which sends the speed setpoint
to the ESM controller depending on the compressor load.
Compressor load is controlled by controlling speed & recycle control
valve opening.
ESM governs the engine speed & has complete engine protection
logics.
ESM-1 Driven engines have dedicated controller for cylinder
temperature measurement & protection. In ESM-2 the same is
integrated with ESM controller.
Engine Control System
Start Flow diagram Stop Flow diagram
Shutdown
Engine Controls
Speed Control
Air-Fuel-Nox Control
Ignition Control
Turbocharger Control
Auxiliaries
Speed Control
Speed Control
Ignition Control
Turbocharger Control
NOx Control
Auxiliaries - Lube oil, Cooling water &
Jacket
Engine has Trip on,
water
Low Lube oil Level.
High lube oil temperature.
Low lube oil Pressure
Low jacket water level, low auxiliary water level
High jacket water temperature
Diagnostics & Troubleshooting
ESP (Electronic Service Program) & E-Help software interface is
used for communicating to Engine controller ESM.
ESP shows the real time values of sensors, status of the engine
& also logs of alarms & trips related to engine.
Each alarm & trip has a fault code. Fault code has the remedies
& tips for troubleshooting.
Screens from ECU Laptop
Interface
Screens from ECU Laptop
Interface
Exhaust & Turbo Temperature
Monitored by Altronics DSM universal temperature scanner.
Engine cylinder temperature & engine bearing temperature are
monitored.
Trip values are defined in this controller.
Digital trip output signal is connected to altronics DE 3000
controller.
Compressor – Ariel KBZ4
Altronics DE-3000 is
used for controlling the
compressor
throughput.
Recycle control valve is
modulated according to
the suction pressure
set point.
Recycle valve also
opens fully if discharge
pressure goes high.
Compressor Instrumentation
Suction pressure
Discharge Pressure
Discharge Temperature
Drive Speed
Scrubber Level
Scrubber Temperature
Bearing Temperature
Lube oil Pressure
Lube oil Temperature
Lube oil level
Cylinder head oil no flow
Compressor vibration
Cooler fan vibration
Jacket water & Coolant water level
Crankcase pressure
Compressor Control
Problems Faced
Engine side:
Trip without actual alarms.
Over crank alarm.
Actuator Linkage Stuck.
Component failure.
Condensation inside stepper.
Problems Faced
Compressor side:
Trip without actual alarm (Manual stop).
Lube oil level switch malfunction
Vibration switch
Maintenance practices
implemented
In every 1000 Hours Maintenance apart from OEM
recommendations,
All harness, switches, sensors, coils are thoroughly inspected.
Earthing studs are cleaned & maintained.
Wiring inside the emergency push button inspection for any
damage.
Stepper regulator inspection, cleaning & lubrication will be
done.
Modification of tubing for stepper regulator is being
implemented to avoid condensation.
Calibration of actuators.
QUESTIONS?
?
THANK
YOU..!!