Technology Solutions


The control of rotating equipment like turbines, compressors and steam driven pumps is a mission critical application, hence it requires a suitable control and safety system. The RTP3000 TAS N+ fully integrated control and safety system meets all the requirements for turbomachinery applications. The RTP3000 TAS N+ is SIL 1-3 approved by TÜV to run both control and safety functions in the same controller. Therefore, safety functions like for example overspeed protection can be executed in the same controller as the control applications in a fully integrated environment.

So, why do we need to control and optimize the performance of turbines and compressors? The number one priority for energy companies around the world is the safety of its personnel and its assets. Poorly executed control strategies can lead to loss of life and extensive mechanical damage to the machine, which results in lengthy and costly downtime of operations in addition to all sorts of issues with liability.

A 30-year lifecycle cost for a 20,000 hp compressor is calculated to $186M. Over 96% of the lifecycle cost is energy cost to operate the compressor. The energy cost can be reduced if correct measures are taken. Poor control, the use of non-integrated systems, and applications relying on theoretical parameters can lead to higher operational costs, higher maintenance, and unnecessary limitations of production.

Steam turbine and extraction control provide close boundary control of steam turbines to increase production and efficiency, while minimizing overspeed situations.

Gas turbine control of the gas fuel valve and guide vane position maintains the required frequency or power. This application is typically integrated as part of a Total Train Control system.

Surge protection control safeguards the machine by preventing compressor surge and at the same time saves energy by keeping the compressor as close as possible to the point where operating costs are lowest. It ensures a minimum safe volumetric flow rate through the compressor while preventing compressor surge by manipulating the recycle valve.

Performance or capacity control maintains a primary process variable with up to two limiting PID’s, being suction & discharge pressure and flow through the compressor, to prevent the suction valve from opening and to provide a more stable and reliable process control.

Master control is for stations with groups of turbomachinery units – whether in series, parallel, or a combination of the two – and for groups of stations. The master control solution is used to control and distribute load at the unit and station level. The solution has two primary functions which are load sharing and load balancing and is available for motor-driven, reciprocating-driven and turbine-driven compressors. Load sharing effectively distributes load according to the requirements of the process. Load sharing distributes the load across units and stations and determines the best operating scenarios for both control levels. Load balancing is an optimized strategy that balances load across all units and stations based on specific balancing criteria, keeping the operating point on equal distance from the surge line.