CONTROL SYSTEMS

OPERATION

CONTROL SYSTEM

For

ONE (1) MOTOR/COMPRESSOR RECIPROCATING

PACKAGE

Prepared For

PetroEcuador Refineria

Esmeraldas,Ecuador

DRESSER-RAND CONTRACT CT133374

1202 WEST SAM HOUSTON PARKWAY NORTH
HOUSTON, TEXAS 77043
(713) 467-2221

2014, Dresser-Rand Company

 Revision Record

2014, Dresser-Rand Company

Revision Date Remarks

Rev. 0 10/14/2014 Manual Initial Issue

Note: The documents contained within this DRmanual (Engineer write-ups, drawings,
Submanufacturer Literature, etc.) have independent revisions levels, they are not
dependent on the overall DRmanual revision level.

Prepared by TV Comments:
Checked by RS
Approved by CM
Date 10/14/2014
PetroEcuador Refineria Esmeraldas, Ecuador Page 1 of 1
CT133374 Rev. 0, October 2014
 Table of Contents

2014, Dresser-Rand Company

I. CONTROL NARRATIVE

II. HUMAN MACHINE INTERFACE (HMI) OPERATION

APPENDIX A: ENVISION HMI MANUALS
APPENDIX B: D-RCS CONTRACT SPECIFIC HMI SCREEN SHOTS

III. D-R HOUSTON CONTROLS DRAWINGS/DOCUMENTS

APPENDIX A: D-R CONTRACT DRAWINGS/DOCUMENTS

IV. BILLS OF MATERIAL/SUBMANUFACTURER LITERATURE

APPENDIX A: BILLS OF MATERIAL
APPENDIX B: BENTLY NEVADA SUBMANUFACTURER LITERATURE
APPENDIX C: TRICONEX SUBMANUFACTURER LITERATURE

V. CUSTOMER INFORMATION/SUPPORT

PetroEcuador Refineria Esmeraldas, Ecuador Page 1 of 1

CT133374 Rev.0, October 2014
 Control Narrative
Section I
2014, Dresser-Rand Company

The Control Narrative follows this page and has been inserted into this DRmanual in the
same format and structure that has been transmitted throughout the course of the
project.

PetroEcuador Refineria Esmeraldas, Ecuador Page 1 of 1

CT133374 Rev.0, October 2014
 Description of Operation

CONTROL SYSTEMS

Functional Design Specification

(Control Narrative)

Control System For

One (1) Motor/Compressor Reciprocating Package
D-R Document No. :665-753

Prepared for

PetroEcuador Refineria
Esmeraldas,Ecuador
DRESSER-RAND CONTRACT 133374
DRESSER-RAND CO.

1202 WEST SAM HOUSTON PARKWAY NORTH

HOUSTON, TEXAS 77043

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CT133374 Rev.1 Sep 15, 2014
 Description of Operation

Hydrogen Rich Reciprocal Gas Compressor (P2-CO2 C)

The following is a general description of the Local Control Panels (LCP) supplied with
Dresser-Rand Control Systems Contract 133374 for the PetroEcuador Refineria
Esmeraldas project.
The primary control device for the compressor train in this system is a Triconex Trident
Triple Modular Redundant (TMR) PLC configured for processing of Analog and Discrete
Variables, Control Logic Sequencing, and Alarm/Shutdown Protection. Generally, field
I/O is directly connected to the I/O Baseplates within the panels unless signal isolation
or conditioning is required.
The LCP P2-CO2 C contains the Trident PLC main processors, communication
modules, I/O modules and base plates, push-buttons and selector switches for
controlling the Compressor Train, 24 VDC power supplies, the HMI computer/ display
monitor, and required communication hardware. The PLC is designed to provide for
Condition Monitoring, Start/Stop Sequencing Loading & Unloading, Alarm monitoring,
and Shutdown protection for the Motor/Compressor trains.

Trident PLC I/O Modules and Baseplates are located within the LCP for I/O
termination. The I/O Modules acquire discrete and analog signals from the
equipment located near the LCP, including the Distributed Control System
(DCS), the Switchgear, and the Motor Control Center (MCC).

Communication equipment required to interface with the Human Machine

Interface (HMI) computer is located within the LCP. The DCS gathers train
operating data through Trident redundant Modbus connections. The HMI
computers communicate with the Trident PLC through an Ethernet Network
to the Trident Communication Modules.

A hardened, HMI computer is installed in the LCP. The LCP-mounted HMI

display is a 19-inch LCD color monitor

Redundant, 40-amp, 24 VDC Phoenix Quint power supplies are mounted

within the LCP to supply 24 VDC power to field instrumentation and
communication equipment and power to the PLC for logic execution, as
required. The supplies are completely independent, allowing on-line
replacement of a failed power supply without affecting the running process.

The compressor start/stop sequencing is controlled by pushbuttons on the

face of the LCP. Selector switches control the operation of the Crankcase
Heater and Aux. Lube Oil Pump.

A purge/pressurization system is incorporated in the Local Control Panel to

maintain a positive pressure in the enclosure to prevent hazardous gas
from entering.

A Vortex cooler is provided for panel cooling. The Vortex Cooler is provided
as a stand-alone unit. It is powered by 24 VDC and has its own electronic
temperature sensor. The temperature setting for the on/off operation on the

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CT133374 Rev.1 Sep 15, 2014
 Description of Operation

cooler is adjusted on the individual unit. A one-way valve prevents leakage

from the vortex exhaust when the cabinet cooler is not in operation.

The control system includes one (1) Human Machine Interface computer
running a copy of the Dresser-Rand HMI application. The LCP HMI consists
of a 19 LCD touchscreen display, Vartech computer with a panel-mounted
keyboard and mouse installed within the purged enclosure.

I. The following items are located on the Local Control Panel (LCP) for the Hydrogen
Rich Reciprocal Gas Compressor (P2-CO2 C). These are listed by Description, Item
Number, and the associated Dresser-Rand Schematic Reference Number (in
parentheses) as indicated on the LCP Face Layout Drawing, Dresser-Rand Drawing
663-748.
Note: Refer to this manual and/or the contract drawings for further detail.

A. OPERATOR INTERFACE

1. OPERATOR INTERFACE MONITOR, ITEM 8 (HMI-601) The monitor

(Operator Interface) displays various screens of compressor train data.
Each screen has been specifically designed for this application. The
screens provide a graphic and tabular display of analog values,
operational status information, and system alarm and shutdown
conditions.

2. HORN, Item 4 (HN-2008) - An audible indication of an Alarm or Shutdown

condition monitored by the LCP. The horn is silenced by depressing the
Horn Silence pushbutton (PB-1007).
Note: Refer to the Operator Interface section of this manual for a complete
listing of the information available for display on the Operator Interface.

3. KEYBOARD/ MOUSE, ITEM 6 (KB-601) The keyboard and panel

mouse mounted on the face of the panel is used for navigating and
making selections on the Operator Interface.

B. MISCELLANEOUS

1. NAMEPLATE, ITEM 94A The warning nameplate Not For General Use
is to be placed near the UPS receptacle.
Note: This receptacle is to be designated for use by equipment requiring
UPS power. Overloading this receptacle may result in overloading of the
UPS and consequentially the compressor control system power supply
system.

2. INTERIOR LIGHT SWITCH, ITEM 93 (LT-701) This panel interior light

(LT-701) illuminates when the Interior Light Switch (SS-701) is placed in
the ON position on the face of the panel.

3. PANEL EXTERIOR LIGHT, ITEM 2 (LT-702) This panel Exterior light is

an explosion proof lamp and illuminates when the Exterior Light Switch
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 Description of Operation

(SS-702) is placed in the ON position on the face of the panel.

4. EXTERIOR LIGHT SWITCH, ITEM 31 (SS-702) This panel Exterior light

illuminates when the Exterior Light Switch (SS-702) is placed in the ON
position on the face of the panel.

C. PRESSURIZATION SYSTEM

1. ATMOSPHERIC PRESSURE SENSE CONNECTION, ITEM 45 - Provides

atmospheric reference for the Differential Pressure measurements.

2. PANEL PURGE DIFFERENTIAL PRESSURE, ITEM 44 (PDG-7001),

Provides visual indication of the LCP purge pressure.

3. PANEL PURGE SUPPLY PRESSURE, ITEM 44 (PI-7001), - Provides

visual indication of the supply pressure to the LCP.

4. PANEL PURGE FLOW INDICATOR; ITEM 44 (FI-7001), Provides a

visual indication of the purge airflow through the LCP.

5. PANEL PURGE RELIEF VALVE, Item 43 (PRV-7001) The enclosure

protection vent allows enclosure purge air to escape the enclosure to
guard against enclosure over-pressurization and possible explosion due to
over-pressurization.

6. PURGE AIR SUPPLY, Item 42 The enclosure air supply point of entry.
The instructions on the nameplate must be followed for proper panel
purging.

7. PRESSURE SWITCH LOW ENCLOSURE PURGE FAILURE, ITEM 96

(PDSL-7001), Tag P2-PDSL-485-C The panel purge and pressure low
switch (mounted inside the panel) monitors differential pressure between
internal enclosure pressure and ambient pressure. Low differential
pressure indicates that the enclosure purge system has failed and
requires service. A Panel Enclosure Low Purge Pressure Alarm is
annunciated when this switch indicates a low differential purge pressure.
This switch should be calibrated to 0.1 inches of water differential
decreasing for proper purge system operation.
Note: Refer to the Sub manufacturer Literature section of this manual for a
full system description of operation.

8. NAMEPLATE, ITEM 46 The LCP warning nameplate for the rear access
door and on the face of the panel is Warning Purged Enclosure.

D. PUSHBUTTONS
1. UNIT LAMP TEST, ITEM 27 (PB-1006), - This black pushbutton, when
depressed, will illuminate all of the pilot lights located on the face of the Local
Control Panel for purposes of testing it for proper operation
2. COMRESSOR UNIT EMERGENCY SHUTDOWN ESD ITEM-09 (ESD-1003),
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 Description of Operation

This red PUSH-TO-TRIP mushroom type pushbutton initiates an Isolated

Emergency Shutdown of the compressor.
3. COMPRESSOR START, ITEM 20 (PB-1001) Once a Motor Start
Permissive has been indicated, this green pushbutton, when pressed, allows
the operator to initiate a start sequence of the motor/compressor.
4. COMPRESSOR NORMAL STOP, ITEM 21 (PB-1002) This red pushbutton,
when depressed, initiates a Normal Stop sequence of the Motor/Compressor.
5. CAPACITY LOAD STEP UP, ITEM 25 (PB-1009), This black pushbutton,
when pressed, loads the compressor in step increments.
6. CAPACITY LOAD STEP DOWN, ITEM 26 (PB-1010)This black pushbutton,
when pressed, unloads the compressor in step increments.
7. ALARM ACKNOWLEDGE, ITEM 22 (PB-1004) Depress this black
pushbutton to acknowledge any alarm or shutdown listed on the alarm
summary of the operator interface.
8. ALARM RESET ITEM 23 (PB-1005) Depress this black pushbutton to reset
any alarm or shutdown listed on the alarm summary of the operator interface.
9. HORN SILENCE ITEM 24 (PB-1007) Depress this black pushbutton to
silence the alarm/shutdown horn.

E. SELECTOR SWITCHES AND PILOT LIGHTS

1. AUXILIARY LUBE OIL PUMP HOA Item 30 (SS-1012)- This selector

switch allows selection of one of the following modes of operation:

HAND The HAND mode of operation enables the operator to

select the Lube Oil Pump to start. The pump will continue to
operate until the switch is changed to the OFF position.

OFF The OFF mode turns off the Frame Lube Oil pump.

AUTO The AUTO mode allows the Lube Oil Pump to start based
on loss of Main L.O Bearing Pressure.

Note: After the compressor is up and running the Aux, pump should be selected
for AUTO operation.

2. COMPRESSOR PERMISSIVE TO START, Item 10 (PL-2001), - This

Amber pilot lamp will illuminate when all conditions required to enable
starting of the Compressor Unit have been satisfied.

3. COMPRESSOR STOPPED, Item 21 (PL-2002) - This blue indicator lamp

will illuminate when the Unit Normal Stop Sequence has been activated
from the LCP. The lamp will remain illuminated until a Permissive Start
has been established or a Shutdown condition has been detected.

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 Description of Operation

4. COMPRESSOR RUNNING, Item 11 (PL-2002) - This green indicator lamp

will be energized once the Main Drive Motor is running and will be de-
energized when the Compressor has been stopped or tripped.

5. COMPRESSOR EMERGENCY SHUTDOWN, Item 14 (PL-2007) - This

red pilot lamp will illuminate when an EMERGENCY SHUTDOWN has
been activated. It will remain illuminated until the ESD has been cleared
(returned to normal) and Reset.

6. COMPRESSOR COMMON ALARM, Item 15 (PL-2004) - This red pilot

lamp will illuminate when an Alarm condition has been detected. It will
remain illuminated until all Alarm conditions have been cleared (returned
to normal) and Reset.

7. COMPRESSOR SHUTDOWN ALARM, Item 16 (PL-2005) - This red pilot

lamp will illuminate when a Shutdown condition has been detected. It will
remain illuminated until all Shutdown conditions have been cleared
(returned to normal) and Reset.

8. AUXILIARY LUBE OIL PUMP RUNNING, Item 13 (PL-2006) - This red

pilot light will be illuminated anytime the Aux pump is running scheduled or
unscheduled.

II. LOCAL CONTROL PANEL POWER DISTRIBUTION

Critical Power Bus 1 (UPS), 120VAC, 60 Hz. is supplied by the customer to the
Main Disconnect MACB-01 on BUS-701A. Critical Power Bus 2 (Normal),
120VAC, 60 Hz. is supplied by the customer to the Main Disconnect MACB-02
on BUS-701B. Utility power 120VAC, 60 Hz. is supplied by the customer to the
Main Disconnect MACB-03 on Bus-705.
The following Fuses, Disconnect Switches, and accessories are located inside
the LCP. They are listed by the description, followed by the Fuse Number.
Note: Refer to the LCP Schematic Wiring Diagram 665-749, sheets 7-7c for
wiring details and other relevant information.

F. BUS-701A (120VAC)
This is a three-pole comb bus bar, rated for 100 Amps, used to distribute
120VAC power from the Main Disconnect MACB-01 for the individual load fuses.
Disconnect Switches are DIN-rail mounted.

1. 120VAC UPS POWER MAIN DISCONNECT (MACB-1) Supplies/

removes the 120VAC power to the devices in the LCP connected to BUS-
701A. The devices powered from the Main Disconnect are indicated
below.

CAUTION

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 Description of Operation

THE MAIN DISCONNECT DOES NOT REMOVE ALL POWER

SOURCES. PRECAUTIONS MUST BE TAKEN TO AVOID ELECTRICAL
SHOCK AND INJURY TO PERSONNEL.

2. DC POWER SUPPLY No. 1 PS-701 (120VAC-01) - Supplies/removes

120VAC to 20-Amp DC Power Supply No. 1 (PS-701) which provides
24VDC power to BUS-703 which provides 24VDC power to PLC Logic
Power 1 connections.

3. VM-6001 VIBRATION MONITOR (120VAC-02) - Supplies/removes

120VAC to the Vibration Monitor Power Supply No. 1

4. SPARE (120VAC-03) Spare 10 amp 120VAC UPS fused power.

5. OPERATOR INTERFACE (120VAC-04) Supplies/removes 120VAC

power to the HMI monitor (HMI-601).

6. DC POWER SUPPLY No. 3 PS-703 (120VAC-05) - Supplies/removes

120VAC to 5-Amp DC Power Supply No. 3 (PS-703) which provides
24VDC power to loader solenoid valves.

7. SPARE (120VAC-06) Spare 10 amp 120VAC UPS fused power.

G. BUS-701B (120VAC)
This is a three-pole comb busbar, rated for 100 Amps, used to distribute 120VAC
power from the Main Disconnect MD-2 for the individual load fuses. Disconnect
Switches are DIN-rail mounted.

8. 120VAC NORMAL POWER MAIN DISCONNECT (MACB-02)

Supplies/removes the 120VAC power to the devices in the LCP connected
to BUS-701B. The devices powered from the Main Disconnect are
indicated below.

CAUTION

THE MAIN DISCONNECT DOES NOT REMOVE ALL POWER

SOURCES. PRECAUTIONS MUST BE TAKEN TO AVOID ELECTRICAL
SHOCK AND INJURY TO PERSONNEL.

9. DC POWER SUPPLY No. 2 PS-702 (120VAC-06) - Supplies/removes

120VAC to 20-Amp DC Power Supply No. 2 (PS-702) which provides
24VDC power to BUS-704.

10. VM-6001 VIBRATION MONITOR (120VAC-07) - Supplies/removes

120VAC to the Vibration Monitor Power Supply No. 2

11. SPARE (120VAC-08) Spare 10 amp 120VAC UPS fused power.

12. OPERATOR INTERFACE (120VAC-09) Supplies/removes 120VAC

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 Description of Operation

power to the HMI monitor (HMI-601).

13. SPARE (120VAC-10) Spare 10 amp 120VAC UPS fused power.

H. BUS-702 (24VDC)
This is a two-pole comb busbar, rated for 100 Amps, used to distribute 24VDC
power from Power Supply PS-701 to the individual load fuses. Disconnect
Switches are DIN-rail mounted.

1. DIGITAL INPUT FIELD POWER 1 (24VDC-01) - Supplies/removes

24VDC field power to the Digital Input and Digital Outputs modules and
their respective circuits.

2. ANALOG FIELD POWER 1 (24VDC-02) - Supplies/removes 24VDC field

power to the Analog Input modules and their respective circuits.

3. ETHERNET SWITCHES (24VDC-03) - Supplies/removes 24VDC power to

the communication.

4. PLC Rack Power 1 (24VDC-04) - Supplies/removes 24VDC power to the

Trident Controller Base plate...

5. SPARE (24VDC-05) - Spare 24VDC fused power.

I. BUS-703 (24VDC)
This is a two-pole comb busbar, rated for 100 Amps, used to distribute 24VDC
power from Power Supply PS-702 to the individual load fuses. Disconnect
Switches are DIN-rail mounted.

6. DIGITAL INPUT FIELD POWER 2 (24VDC-06) - Supplies/removes

24VDC field power to the Digital Input and Digital Outputs modules and
their respective circuits.

7. ANALOG FIELD POWER 2 (24VDC-07) - Supplies/removes 24VDC field

power to the Analog Input modules and their respective circuits.

8. ETHERNET SWITCHES (24VDC-08) - Supplies/removes 24VDC power to

the communication.

9. PLC Rack Power 2 (24VDC-09) - Supplies/removes 24VDC power to the

Trident Controller Base plate.

10. SPARE (24VDC-10) - Spare 24VDC fused power.

J. BUS-704 (24VDC)
This is a two-pole comb busbar, rated for 100 Amps, used to distribute 24VDC
power from Power Supply PS-701 and PS-702 to the individual load fuses.
Disconnect Switches are DIN-rail mounted.

11. SPARE (24VDC-11) Spare 24VDC fused power.

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 Description of Operation

12. DAQ System (24VDC-12) - Supplies/removes 24VDC field power to the

DAQ-01.

13. SPARE (24VDC-13) - Spare 24VDC fused power.

K. BUS-704 (24VDC)
This is a two-pole comb busbar, rated for 100 Amps, used to distribute 24VDC
power from Power Supply PS-703 to the individual load fuses. Disconnect
Switches are DIN-rail mounted.

14. Loader Solenoids (24VDC-14) - Supplies/removes 24VDC power to the

loader solenoids.

L. BUS-705 (120VAC)
This is a two-pole comb busbar, rated for 100 Amps, used to distribute 120VAC
utility power from the Main Disconnect MACB-03 for the individual load fuses.
Disconnect Switches are DIN-rail mounted.

1. 120VAC UTILITY POWER MAIN DISCONNECT (MACD-03)

Supplies/removes the 120VAC power to the utility devices in the LCP. The
devices powered from the Main Disconnect (MACD-03) are indicated
below.

CAUTION

THE MAIN DISCONNECT DOES NOT REMOVE ALL POWER

SOURCES. PRECAUTIONS MUST BE TAKEN TO AVOID ELECTRICAL
SHOCK AND INJURY TO PERSONNEL.

2. INTERIOR AND EXTERIOR LIGHTS (120UP-01) Supplies/ removes

120VAC power to the Local Control Panel interior and exterior light
switches/lamps.

3. CONVENIENCE RECEPTACLE(120UP-02) Supplies/ removes 120VAC

power to the utility receptacle (RCPT-701)

4. SPARE (208UP-03) Spare 10 amp 120VAC fused power.

III. DESCRIPTION OF OPERATION

This section is the Description of Operation for the Compressor (P2-CO2 C)
control system for Start-up, Sequencing, and On-Line Operation of the Motor/
Compressors and auxiliary equipment.

M. LCP PRE-START
Ensure that the area around the LCP is free of explosive gases prior to
energizing any electrical circuits to the LCP.

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 Description of Operation

WARNING

DO NOT ENERGIZE ANY ELECTRICAL CIRCUITS TO THE LCP UNTIL

THE AREA AROUND THE LCP IS KNOWN TO BE FREE OF
EXPLOSIVE GASES.
1. All AC Fused Disconnects in the LCP must be closed to supply power to the
internal components of the LCP.
Note: The following discussion assumes that the initial TRIDENT PLC
checkout procedures have been completed. Refer to the TRIDENT
Planning and Installation Guide, Chapter 3 Installation and Maintenance,
prior to initial system operation.
2. Ensure that the instrument air supply is available at the panel, and that the
purge air manual shut-off valve inside the panel is open. Close all doors to
ensure a good air seal within the panel.
3. The Local Control Panel is supplied with a type Z purge system. The panel
has a purge local pressure indicator and also a low purge pressure switch for
alarming purposes. The UCP is required to have four (4) air changes with a
flow of 1800 SCFH for 21 minutes. This will pass the required volume
through the enclosure. A red nameplate located on the front access door
provides additional information.
.

N. LOCAL CONTROL PANEL PRE-START

1. All AC Fused Disconnects in the Local Control Panel (LCP) must be closed to
supply power to the internal components of the LCP.
Note: The following discussion assumes that the initial TRIDENT PLC
checkout procedures have been completed. Refer to the TRIDENT
Planning and Installation Guide, Chapter 3 Installation and Maintenance,
prior to initial system operation.

2. Verify that the TRIDENT PLC is powered and that the main processors are
executing the control program as indicated by flashing of the MP Active
LED's.

3. When HMI is powered up and the correct login passwords are entered, the
Microsoft operating system, the DR-HMI Operator Interface application,
and all required Communication, Logging, and Trending software packages
will start automatically.

4. Verify that communication between the TRIDENT PLC and the DR-HMI
touchscreen in the LCP has been established, and that the communication
links are operational.

5. Close all breakers to the Motor Control Center (MCC) equipment after making
sure each device is selected for Automatic (AUTO) operation and verifying
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 Description of Operation

that all personnel are clear of any automatically starting equipment.

6. Acknowledge any active alarms and reset inactive alarms by selecting the
<<Alarm>> tab from the top of any of the DR-HMI Mimic screens and
selecting Reset and Ack All on the bottom of this screen. Review any active
alarms and take appropriate action to clear any undesirable alarms or
shutdowns.

O. LUBE OIL SYSTEM

LUBE OIL SYSTEM START UP SEQUENCE

The compressor Lube Oil System consists of one (1) motor driven Auxiliary
Lube Oil Pump (AOP) with Hand/Off/Auto (H-O-A) selector switches mounted
on the Compressor Local Control Panel (LCP) and one (1) shaft driven Main
lube oil pump.

To prepare the Compressor for starting, reset all alarms associated with the
lube oil system. The Auxiliary Oil Pump (AOP) should be started manually.
This is accomplished by placing the AOP HOA selector switch in the HAND
position. When the HAND position is selected at the H-O-A selector switch,
the Auxiliary Lube Oil pump will start. The pump will continue to operate until
the OFF position is selected.

The PLC will energize Frame Auxiliary Oil Pump Start Command. An AOP
MCC feedback timer (5 seconds) is started and used to confirm AOP Running
feedback from the MCC .On receipt of this signal, the AOP Running indication
lamp will illuminate. Otherwise the PLC will generate an AOP MCC Feedback
Failure Alarm. The Compressor will be inhibited from starting at this point.

Once the Compressor has been started, the shaft driven Main Lube Oil Pump
will be in operation. If the Main Lube Oil Bearing Pressure is healthy (> 2.46
kg/cm^2G), the AOP may be stopped by putting the HOA switch in the OFF. It
should then be placed in standby mode by placing the AOP HOA selector
switch in the Auto position. The operator should investigate the cause of the
pressure drop and take corrective action as necessary. The AOP may be
stopped manually by the operator once the Main Lube Oil Bearing Pressure
has returned to a healthy condition (> 2.46 kg/cm^2G). The AOP will not
stop automatically in this case.

If AOP MCC Feedback Failure occurs while the Compressor is running and
AOP is in Auto, the Start output to the MCC will remain true (energized) until
the operator places the HOA switch in the OFF position.

Note: After the compressor has been started and the lube oil pressure has
been established, the auxiliary pump should be selected for 'Auto' operation.
An alarm will initiate if any of the following conditions occur:

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Lube Oil Pump Auto-Start Alarm: An alarm is generated if the auxiliary

Lube Oil pump starts while in AUTOMATIC mode. This alarm will not clear
until the Lube Oil pump is placed in HAND mode.

Aux Lube Oil Pump feedback Failure: An alarm is generated if the

auxiliary Lube Oil Pump does not make the MCC status feedback after a
start command is issued.

Lube Oil Pump Fail To Establish Pressure Alarm: An alarm is

generated if the Lube Oil pump discharge pressure does not exceed 2.11
Kg/Cm^2 within 5 seconds after the PLC issues the command to start the
pump.

Lube Oil Pumps not in AUTOMATIC Mode while Running: An alarm is

generated if the compressor is running and the auxiliary Lube Oil pump is
not in AUTOMATIC mode.

P. START SEQUENCE
Starting or stopping of the compressor can only be accomplished from the
compressor Local Control Panel (LCP). The compressor operational status
may be monitored from any HMI terminal. A compressor start can be initiated
whenever all compressor start permissives on the Status Overview screen
have been satisfied.
Note: This startup operation details the sequence of events and steps
required to start the compressor from a controls standpoint only. Start
requirements detailed in the manuals for the reciprocating compressor, main
drive motor and lube oil system in addition to manuals for any other
equipment associated with this unit must be followed.

1. Below is a listing of the compressor start permissives with a description of

each. Select the Status Overview screen at the HMI and verify that the
following conditions are satisfied:

a. MAIN LUBE OIL PUMP BEARING PRESSURE > 2.46 kg/cm^2G -

This permissive is satisfied when the lube oil header pressure is
greater than 2.46 kg/cm^2G.

b. FRAME LUBE OIL LEVEL > LOW ALARM This permissive is

satisfied when the frame crank case lube oil level is greater than
low alarm.

c. AUXILIARY LUBE OIL PUMP CONFIRMED RUNNING IN HAND -

This permissive is satisfied when the Auxiliary Lube Oil pump
feedback is confirmed closed.
d. COMPRESSOR NOT STARTED OR RUNNING This permissive
is satisfied when the Main Drive Motor is confirmed Stopped

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e. COMPRESSOR UNLOADED - This permissive is satisfied when all

of the compressor unloader outputs are in the unloaded state.

f. ALL SHUTDOWNS CLEARED - RESET REQUIRED This

permissive is satisfied when all Compressor shutdown conditions
are clear. Review the Alarm Summary mimic for any active
shutdowns. Clear any shutdown conditions that exist.

g. PNEUMATIC BARRING RIG - This permissive is satisfied when

the compressor barring rig is not engaged. A closed contact from
the barring device indicates that it is not engaged.

h. FLYWHEEL LOCKING DEVICE - This permissive is satisfied when

the compressor flywheel locking device is not engaged. A closed
contact from the locking device indicates that it is not engaged.

i. SHUTDOWN BYPASS MODE NOT ACTIVE - This permissive is

satisfied when the shutdown bypass is not active.

j. VIBRATION MONITOR SYSTEM OK - This permissive is satisfied

when the compressor vibration system is ok and no faults are
present.

2. The compressor main drive motor is started via the START pushbutton
located on the front of the Local Control Panel (LCP).
Note: Review the Alarm Summary screen for any alarms, review any
active alarms and take appropriate action to clear any undesirable alarms.

3. Once the Start Sequence is initiated, the operator can monitor the start
sequence by selecting the Status Overview screen on the Operator
Interface. During the start sequence the following actions are taken
automatically:
a. When compressor start is initiated, the main driver motor start
signal is pulsed on for 2 seconds to close the main drive motor
breaker. The Stop command is always energized unless a unit
shutdown is present or a unit stop sequence is activated.

b. A check timer (5 seconds) will begin timing to verify that the Main
Drive Motor circuit breaker has closed as confirmed by Main Motor
Running feedback from the Switchgear. If the timer expires before
the Main Motor Running feedback confirmation, then a Main Drive
Motor Switchgear Feedback Failure Shutdown will be initiated.

c. Compressor Run Indication is set when the Main Drive Motor

Breaker status indicates that the breaker is closed. Once the Main
Motor Running feedback has been confirmed, the Main Motor

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 Description of Operation

Running lamp will be illuminated. Upon breaker closure the main

driver motor accelerates to rated speed.

d. Once Main Motor Running status has been achieved the 15-second
Compressor Load Permissive Timer starts timing. The purpose of
the timer is to confirm that the Main Motor has accelerated to rated
speed and settled to a steady state current level before loading the
compressor.

When the above conditions are satisfied, the compressor may be

loaded. The Status Overview screen will indicate that the
compressor is ready to load.

Q. CAPACITY CONTROL

Table J-1

R. COMPRESSOR LOADING
Note: There is a 10 second delay following any load step in either
direction before any subsequent load step is allowed. This will allow the
motor current and the process gas flow to stabilize.

From the 0% initial Load step press the Compressor CAPACITY

STEP UP pushbutton once to load the compressor to the 25%
level.

Note: Whenever the compressor is loaded to the 25% level, the

cylinders will alternate loading every 10 minutes to prevent
overheating.

Press the Compressor CAPICITY LOAD STEP UP pushbutton a

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 Description of Operation

second time to load the compressor to the 50% level.

Press the Compressor CAPICITY STEP LOAD UP pushbutton a

third time to load the compressor to the 75% level.

Press the Compressor CAPICITY STEP LOAD UP pushbutton a

fourth time to load the compressor to the 100% level.

S. UNLOADING

Press the Compressor CAPACITY STEP DOWN pushbutton once

to unload compressor to the 75% level.

Press the Compressor CAPACITY STEP DOWN pushbutton a

second time to unload the compressor to the 50% level.

Press the Compressor CAPACITY STEP DOWN pushbutton a

fourth time to unload the compressor to the 25% level.

Note: Whenever the compressor is loaded to the 25% level, the

cylinders will alternate loading every 10 minutes to prevent
overheating.

Press the Compressor CAPACITY STEP DOWN pushbutton a

fourth time to load the compressor to the 0% level.

Note: Maximum No-Load time limit The Compressor is allowed to run

unloaded (0%) for a maximum of 20 minutes. If the Compressor runtime
at 0% load exceed 20 minutes a No Load Runtime Exceeded
Shutdown will be initiated and the Main Drive Motor will be tripped to
Stop the Compressor

T. NORMAL STOP SEQUENCE

A Normal Stop Sequence is one in which the Compressor is Unloaded
prior to stopping the Main Drive Motor. The Normal Stop Sequence may
be initiated only from the LCP by pressing the Main Motor Stop
pushbutton. The PLC control logic will automatically unload the
Compressor and stop the Main Drive Motor as described below
1. STOP / MANUAL UNLOAD
The compressor can be unloaded from any load level to zero
percent (0%) load level before initiating a stop sequence as follows:

a. Press the CAPACITY LOAD STEP DOWN pushbutton as

required bringing all compressor cylinders to the zero
percent load level.
b. Press the COMPRESSOR NORMAL STOP pushbutton.

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c. The normal stop lamp on the LCP is illuminated and Main

Motor stop output is de-energized to stop the motor.

d. When the Main Drive Motor Stop command is issued, the

AOP Start Command will be energized to start the AOP. This
pump will run for the duration of the Post Lube Timer
(Typically 5 minutes) which will be started after the
Compressor is confirmed stopped. After this timer has timed
out, the AOP will be stopped automatically if the AOP HOA
selector switch is in Auto position. If the switch is in HAND,
the pump will continue to run until the operator switches the
HOA to the off position.
e. The stop sequence may be cancelled at any time during the
automatic unloading by pressing the COMPRESSOR
START pushbutton and reloading the compressor.
f. The Normal Stop Sequence is now complete. The
Compressor may be restarted if the Permissive to Start is
established as described earlier in this section.

2. STOP / AUTOMATIC UNLOAD

The automatic unload Stop Sequence is initiated as follows:

a. Press the COMPRESSOR NORMAL STOP pushbutton.

b. The normal stop lamp on the LCP is illuminated and the
compressor is immediately reduced by one load step, e.g.,
from 100% to 75%.
c. The 15-second Unload Timer starts timing.
d. When the Unload Timer times out, the compressor is
reduced by an additional level, e.g., from 75% to 50%.
e. The Unload Timer is reset and starts timing again for another
15 seconds.
f. The compressor will continue to unload in this manner until
the load level is reduced to zero percent. Then the Main
Motor Stop output is de-energized to stop the Main Motor.
When the Main Drive Motor Stop command is issued, the
AOP Start Command will be energized to start the AOP. This
pump will run for the duration of the Post Lube Timer
(Typically 5 minutes) which will be started after the
Compressor is confirmed stopped. After this timer has timed
out, the AOP will be stopped automatically if the AOP HOA
selector switch is in Auto position. If the switch is in Hand,
the pump will continue to run until the operator switches the
HOA to the off position.

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g. The Normal Stop Sequence is now complete. The

Compressor may be restarted if the Permissive to Start is
established as described earlier in this section.

W. COMPRESSOR SHUTDOWNS

A Shutdown is an abnormal condition that requires an immediate trip of

the Compressor Train without delay for unloading. When a Shutdown
condition is detected, the following actions will occur:

a. The PLC will initiate a Shutdown and display the Shutdown

message on the HMI.

b. The PLC will de-energize all of the Step Unloader Valves to

put the Compressor at 0% Load level. At the same time, the
Main Drive Motor Stop signal to the Switchgear is de-
energized to open the circuit breaker and stop the Motor. A
Compressor Failed to Stop Timer (5 seconds) will begin
timing and if the Main Motor Running status feedback has
not been confirmed open before the timer expires then a
Main Drive Motor Failed To Open Alarm is initiated.

c. When the Main Drive Motor Stop command is issued, the

AOP Start Command will be energized to start the AOP. This
pump will run for the duration of the Post Lube Timer
(Typically 5 minutes) which will be started after the
Compressor is confirmed stopped. After this timer has timed
out, the AOP will be stopped automatically if the AOP HOA
selector switch is in Auto position. If the switch is in Hand,
the pump will continue to run until the operator switches the
HOA switch to the off position.

d. The Shutdown Sequence is now complete.

e. The condition which caused the Shutdown should be

investigated and corrective action taken as required. After
the condition has returned to normal, the Shutdown may be
cleared using the Acknowledge and Reset button located on
the front of the LCP. The Compressor may be restarted if the
Permissive to Start is established as described earlier in
this section.

X. OPERATOR INITIATED TRIPS

All Operator Initiated Trips are isolated shutdowns as described
previously in this manual section. A trip will be generated if the discrete
input for any EMERGENCY STOP pushbutton contact opens for 0.5

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seconds.
CMPR DESCRIPTION TAG
P2-CO2 C Remote Emergency Shutdown (From Control Room) (2oo2) P2-HA-408-C
Emergency Shutdown (From LCP) P2-HS-408-C
Table Q- 1

Note: See Compressor Start/Stop Logic Section for Shutdown Actions.

Y. LOADING VALVE TEST SEQUENCES

A test mode is incorporated in the control logic to allow maintenance
personnel to simulate the loading and unloading sequence by energizing
the loading solenoids for each of the compressor cylinders. The following
procedure describes the activation of the test sequence.

a. Ensure the motor/compressor is unloaded and stopped.

Note: Interlocks in the logic will prevent the Test mode from being
activated if the motor compressor is not in stop mode.

b. Turn Aux Lube Oil pump HAND-OFF-AUTO selector switches to

the OFF position..
Note: Interlocks in the logic will prevent the Test mode from being
activated if the Auxiliary Lube oil pump is in either Hand or Auto
mode.

c. Simulate the Load Sequence. Press the CAPACITY STEP UP

pushbutton as desired to energize/de-energize the Valve Unloader
Solenoids in the order of increasing load percentage.
d. Simulate the Unload Sequence. Press the CAPACITY STEP
DOWN pushbutton as desired to energize/de-energize the Valve
Unloader Solenoids in the order of decreasing load percentage.
Note: The Cylinder Valve Solenoids energize to load the
compressor.

Z. GENERAL ALARMS

Frame Lube Oil Heater Fail to Open Alarm: The Frame L.O.Heater
status must indicate that the heater has stopped within 3 seconds after the
PLC issues the stop command or the Heater Breaker fail to open alarm
will activate.

Aux Lube Oil Pump Start or Running Unscheduled Alarm: An alarm is

generated if the Aux Lube Oil Pump starts while in AUTOMATIC mode.

Aux Lube Oil Pump Feedback Failure Alarm: : An alarm is generated if

the Aux Lube Oil Pump MCC running status feedback is not received
within 3 seconds after starting.

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Aux Lube Oil Pump Fail To Establish Pressure Alarm: Aux L.O. pump
discharge pressure must be greater than 2.11 Kg/cm2G within 5 seconds
after the PLC issues the command to start pump or the pressurize fail
alarm will activate.

Lube Oil Pump not in Auto Alarm: An alarm is generated the Auxiliary
Lube Oil. Pump is not AUTOMATIC START mode while the compressor is
running.

Barring Rig Engaged Alarm: An alarm is generated if the compressor

barring rig limit switch indicates that the barring rig is engaged.

Flywheel Locking Device Engaged Alarm: An alarm is generated if the

compressor flywheel locking device limit switch indicates that the flywheel
is locked.

Normal Stop Activated Alarm: An alarm is generated if the Normal Stop

Sequence is initiated.

Main Drive Motor Breaker Fail to Start Alarm / Shutdown: An alarm is

generated if the motor breaker does not indicate a close feedback within
3.0 seconds of a start command. The start sequence is also aborted.

Main Drive Motor Failed to Open Alarm: A Shutdown alarm is

generated if either the motor breaker does not indicate an open feedback
within 3.0 seconds of a stop command.

Shutdown Bypass Enable Active Alarm: An alarm is generated if The

Shutdown Bypass Enable feature is activated.

Bypass Active Hourly Reminder Alarm: An hourly reminder alarm is

generated every hour while the Bypass is activated. This alarm is active
for 30 seconds before resetting.

Local Control Panel Purge Pressure Low Alarm: An alarm is generated

if the LCP differential purge pressure switch opens indicating a loss of
LCP purge.

LCP 40 Amp 24 VDC Redundant Power Supply 1 Common Trouble

Alarm: An alarm is generated if the 40 amp, 24VDC Power Supplies in
the LCP indicates an active alarm.

LCP 40 Amp 24 VDC Redundant Power Supply 2 Common Trouble

Alarm: An alarm is generated if the 40 amp, 24VDC Power Supplies in
the LCP indicates an active alarm.

LCP 5 Amp 24 VDC Power Supply Common Trouble Alarm: An alarm

is generated if the 5 amp, 24VDC Power Supplies in the LCP indicates an
active alarm.

AA. GENERAL CONTROL SYSTEM ALARMS

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Trident PLC Common Trouble Alarm: An alarm is generated if the

Trident PLC detects any trouble alarms.

At least one Main Processor is out-of-sync or failed.

Two Main Processors have failed or are out of sync. TRIDENT is running
in simplex mode.

Left, Middle, or Right Main Processor fault detected alarm.

Left, Middle, or Right Main Processor not active alarm.

Left, Middle, or Right Main Processor battery fault detected alarm.

Main Processor temperature fault detected alarm.

System Logic Power fault detected alarm.

System Field Power fault detected alarm.

Module Fault detected alarm.

Channel Fault detected alarm.

Voter Fault detected alarm.

Field I/O Fault detected alarm.

Logic Power 1 Fault detected alarm.

Logic Power 2 Fault detected alarm.

Left Communication Module Net 1 fails alarm.

Right Communication Module Net 1 fails alarm.

Trident point disabled alarm. Alarm active if any Trident PLC point is
disabled.

Trident PLC to HMI1 or Ethernet communication failure alarm. Alarm

active if watchdog is not set for 45 seconds.

BB. ALARMS AND SHUTDOWNS

Alarms and Shutdowns are abnormal conditions or malfunctions that are
being monitored by the PLC application logic.

An Alarm condition will not cause the unit to shutdown or stop. However,
operator intervention may be required in order to correct the abnormal
conditions or to keep them from escalating into a Shutdown condition.

A Shutdown is a malfunction that requires an immediate trip of the

Compressor. The operator is alerted to the presence of a shutdown condition
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 Description of Operation

by means of visual indication on the HMI.

There are 3 classifications for the Alarms and Shutdowns that may or may not
be used within this system and the following describes the action of each
class.

1. CLASS A
This classification allows the associated alarm and or shutdown to be
active at all times. Alarm or shutdown action is immediate without time
delay.
2. CLASS B
This classification allows the associated alarm and or shutdown to be
active only after a specific sequence timer within the PLC application has
timed out. Alarm or shutdown action then becomes immediate without
further time delay. In addition, a number of process alarms and shutdowns
are enabled simultaneously by a Common Class B Alarm Delay Timer.
This timer (nominal setpoint 15 minutes) is energized when Compressor
Running status is achieved.
3. CLASS C
This classification allows the associated alarm and or shutdown to be
active only once the variable has exceeded the respective set point for the
first time and usually after some time delay. Once the variable has
exceeded the setpoint or reached a certain criteria a PLC logical latch is
set and then the alarm and / or shutdown is always enabled.

Please refer to Alarm & Shutdown matrix, Dresser-Rand drawing 665-752

for a listing of Alarms and Shutdowns and their classification
CC. VOTED SHUTDOWNS
This project, Voted Shutdowns are implemented as 2 out of 3 (2oo3)
depending on available input signals.

Transmitter Inputs (2oo3)

For 2oo3 Voted Shutdowns based on transmitter inputs, logic is
implemented to consider the shutdown condition (HH or LL per Cause and
Effects) with a healthy transmitter and failed transmitter. A shutdown is
initiated for the following combinations:
Xmtr A shutdown + Xmtr B shutdown
Xmtr A shutdown + Xmtr B failed
Xmtr A failed + Xmtr B shutdown
Xmtr A failed + Xmtr B failed
Xmtr C shutdown + Xmtr B shutdown
Xmtr C shutdown + Xmtr B failed
Xmtr C failed + Xmtr B shutdown

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 Description of Operation

Xmtr C failed + Xmtr B failed

Xmtr C shutdown + Xmtr A shutdown
Xmtr C shutdown + Xmtr A failed
Xmtr C failed + Xmtr A shutdown
Xmtr C failed + Xmtr A failed

DD. ALARM PROCESSING

1. Alarm Suppression

Suppression (or inhibit) of certain alarms and associated actions is

required prior to start, during parts of the start sequence and following
stop/shutdown of the Compressor Train. The PLC program includes
logic to inhibit these alarms automatically so that they do not clutter the
HMI with nuisance alarm indications. These are referred to as Class B or
Class C alarms/shutdowns as indicated on the Alarm & Shutdown
Matrix, D-R Drawing 665-752.
2. Alarm Indication

All alarms (including signal failures, warnings, and shutdowns) will be

reported on the HMI.

3. Alarm Acknowledge

There is no separate ACKNOWLEDGE sequence implemented for

Alarms.

4. Alarm Reset

The operator may reset any alarm/shutdown by pressing the RESET

pushbutton on the face of the LCP. If the original alarm/shutdown
condition has been cleared, the alarm/shutdown message will be
removed from the current alarm/shutdown list; otherwise, the
alarm/shutdown message will remain in the list.

The RESET pushbutton also provides a reset signal to the backup relay
logic and the BENTLY Nevada 3500 series Vibration Monitor.

EE. SHUTDOWN BYPASS

Local Control Panel PLC Shutdown Bypass Enabled

The Shutdown Bypass feature is enabled by a password accessible feature

installed in the HMI on the LCP. This will allow selection/activation of a
Shutdown Bypass from the HMI. The HMI sets a bit in the PLC to be used
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 Description of Operation

in the shutdown logic. An HMI alarm is generated to indicate the Shutdown

Bypass in Effect.

If the Bypass feature is turn to the OFF position, the bypass feature will
be disabled. Any activated bypassed shutdown will remain active. The
Shutdown Bypass Active alarm has a reminder time limit of 60 minutes.
After 60 minutes, a Bypass Active Warning Alarm will notify that a
Shutdown bypass is active. This alarm will activate every hour as a
reminder as long as a Shutdown Bypass remains active.

For voted 2003 voted shutdowns if two (2) of the transmitters are in Signal
Failure condition, the system will initiate a Shutdown. Also if one of the
transmitters has an active bypass, the voting will be adjusted to 2oo2 of the
remaining transmitters. In the case of a Signal Failure of one the remaining
transmitters, the Shutdown will be handled by the healthy transmitter as
1oo1 logic.

CAUTION
WHEN THE SHUTDOWN BYPASSED POINT IS READY FOR
REENABLING, MAKE SURE THAT THE ACTUAL SHUTDOWN
CONDITION HAS BEEN CLEARED FROM THE HMI ALARM /
SHUTDOWN SUMMARY SCREEN ON THE HMI. IF THE POINT IS
REENABLED WHILE THIS SHUTDOWN IS STILL PRESENT WITHIN
THE ALARM / SHUTDOWN SUMMARY SCREEN, THEN THE UNIT WILL
SHUTDOWN ONCE ENABLED.

FF. ANALOG SIGNAL FAILURE

A signal failure is a condition where the value of an analog variable is outside

the defined input range by +/- 2%. There are two categories of signal failure:
Analog points without shutdown limits

Analog points with shutdown limits (High High or Low Low).

Note: For details on specific actions for any given signal failure refer to
the Alarm & Shutdown Matrix, D-R Drawing 665-752

1. Analog Points Without Shutdown Limits

A signal failure for an analog point without shutdown limits will normally
initiate an alarm, and some selected signals will also prevent start-up by
blocking the Unit Start Permissive.

2. Analog Points With Shutdown Limits

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A signal failure with shutdown limits (High High or Low Low) will normally
initiate a shutdown of the Compressor Train.

GG. COMMUNICATION LINKS

There are two types of Communication Links implemented in the LCP:
a. Modbus Communications with DCS
There are two Modbus communication links provided for communication
with the DCS through wiring configuration is documented on the LCP
Schematic Diagram.

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b. Modbus Communications with Bently Nevada 3500 system

A Modbus communication link is implemented between the PLC and
Bently Nevada series 3500 Vibration and Temperature monitoring system.
This link connects between the Trident communication module in the PLC
and the 3500/92 Communication Gateway in the BN3500 system rack.

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 Human Machine Interface (HMI) Operation
Section II
2014, Dresser-Rand Company

The Human Machine Interface (HMI) System is the primary means by which an operator
can view the process and machinery being controlled. Using graphical screen
presentations the HMI allows the operator to monitor the health and current status of the
system. It provides alerts and alarms when the process is approaching dangerous
conditions. The HMI system through keyboard, pointing device or touch-screen gives
the operator a method of starting, stopping and controlling the machinery and
processes. It provides a means to select information to be displayed, and to change
values such as set points, analog limits and timer preset values. The Logic Controller
then uses these values to control the process/machine. The HMI allows the operator to
see the current conditions of analog and discrete inputs, timers, alarms and shutdowns,
as well as other operational status information. It displays the data from the process
both numerically and graphically. The process data is saved by the HMI on its hard
disk. These records are archived to facilitate the generation of reports and to allow
historical data to be reviewed at a later date. The operator can trend data gathered
over long periods to highlight slow changes or to review causes of past process upsets.
Status events and alarm records are also recorded and archived. The graphical
screens in the HMI provide the tools to review, search, sort and print these historical
records.
The HMI software and hardware provide the interface protocols, server functions and
connectivity to allow the gathering, archiving and sharing of process data. The HMI has
the capability to communicate with one or multiple PLCs and other types of controllers
and data-gathering devices. It can communicate either serially or over any of several
networks. Refer to the project schematic drawings and the Communication Screen on
the HMI (illustrated later in this section) for the data flow and connections of this
application. The HMI system also makes it easy to share data. It has a built in Global
Access Web server. Global Access allows a person to view screens on a remote PC.
The remote user merely connects to the HMI over a network using an Internet browser.
Upon obtaining security clearance of the network and the HMI application display
screens are sent to the remote PC. The HMI can be developed to allow either a view
only or a view-and-control remote connection to the application. The HMI system also
has a built in OPC server that allows a data connection from external devices to the
tags in the HMI. DCS systems or other OPC clients on the shared network can connect
and gather data from the sysem. Another method the HMI can use to share data is as a
Modbus device. The HMI PC can be set to mimic a Modbus slave that can respond
either serially or over a TCP/IP network connection to a Modbus master that is polling it
for data. Additionally the HMI system can share data between its tags and the tags of
another DR HMI system. This is most helpful in creating redundant HMI systems. Yet
another way to transfer data to and from the HMI system is to connect to an external
database. This database can be any of several standard databases. It can be on the
same PC as the HMI or it can be across a network connection. This allows the HMI to
save data to an open database that other users or programs have access to.

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Section II Human Machine Interface (HMI) Operation

A. HARDWARE FOR THE HMI SYSTEM

Refer to the appropriate Bill of Material for computer specifications.
The System also includes a USB connected hardware license for the DR HMI
software (refer to the Software and Licenses for the HMI System Section).

B. SOFTWARE AND LICENSES FOR THE HMI SYSTEM

The Software installed on the PC by Dresser-Rand includes the DR HMI Web
Studio Program configured to run in the Windows XP Operating System
environment. Secondly a DR HMI Application with all of the graphical screens,
data variables, alarm and scan tables is installed on the PC. The DR HMI Web
Studio program runs the HMI application to gather data and display it on the local
display. The DR HMI Web Studio is installed with Development Tools as well as
a Runtime program. The installed DR HMI also includes more than 30
communications drivers for communicating with PLCs and controllers. It includes
OPC and Web servers. It includes all historical and database interfaces.
However not all of these capabilities of the DR HMI are enabled. The software is
enabled by a hardware license plugged into one of the USB ports. This license
will determine such things as how many communication drivers or Global Access
connections the application will allow. Check the Bill of Material list in this
manual to determine what DR HMI functions have been enabled on the license.
The application includes a tag database of variable descriptions and definitions
that are found in a set of spreadsheet files with the application. Open Office
software has been installed on the computer to facilitate viewing and
manipulation of these spreadsheet database files. They also can be viewed and
manipulated using the Microsoft Excel program (which is not installed on the HMI
PC).

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Section II Human Machine Interface (HMI) Operation

C. SCREEN LAYOUT AND NAVIGATION

The Screens in the HMI application have a structure and layout that is consistent
throughout the application. Each screen is divided into three major sections.
There is the header portion. This section has the name of the equipment or
location, the last alarm, some hot button icons and the tabs for navigation. The
second portion of the screen is the body. It contains the graphics and data of the
process or machine. Any controls or data entry will be initiated from the body
portion of the screen. Most data entry or action will include pop-up dialog boxes
to complete the entry. The bottom part contains communication information, time
and date and current user. An example of a screen is shown below with the
elements identified.

Header

Body

Status

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Section II Human Machine Interface (HMI) Operation

Header Details
Print
Hot buttons Module: Project Name Previous Logon
Exit

Menu Pull Down Last Alarm Navigation Tabs

Header icon actions are shown in the figure above. The Menu Pull down button
will cause a menu to drop down. The user can use this to navigate to other
modules in the system or other compressor stages if that is the case. The
Previous page icon will jump the user back to the previous screen. Pressing it a
second time will return to the page you started from. The navigation tabs will
take the user to the indicated screen. Right upper corner is the logon icon. This
pops up a dialog box that allows a new user to sign on. Different users will have
different security levels and thus different actions that they will be allow to do.
Next is the print icon. This will cause the current screen to be printed to the
default printer. The printer can be a network or a local printer. If there is no
printer connected or no printer setup for the HMI PC then no action will take
place. Next to the print icon is the page setup icon that allows the user to set up
such things as the page margins, orientation and other print characteristics
before printing. The Exit icon will stop the application and return to the operating
system. If you are not signed on with the proper security level, you will not be
able to stop the application or get to the Operating system.
Note: For further detail you may also reference a Microsoft HTML Help File
named D-R HMI Studio (DHS) Technical Reference located on the HMI PC at
the following address: C:\Program Files\DR HMI Studio v7.1\Bin\. This file is also
available in the electronic version of the DRmanual in a separate file on the CD
named TechRef.chm.

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D. MENU DESCRIPTION AND ACTIONS

Clicking on the button on the header will cause the menu to drop down (as
illustrated below). This menu is used basically to change between modules, not
being required to navigate between the mimics. Six modules are available
depending on the project and can be reached by pressing the respective buttons.
They will be grayed out when not available. Each module brings its own tabs for
navigation.

Select the set of tabs for each

stage or machine. This also can
be done using the hot buttons.

Open the summaries

tabs for analog, status,
timers and limits.

Modules

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1. INFORMATION MODULE
The Information Module provides general information about the system,
which can be visualized using any of the following interfaces (tabs).

HOME: Provides a visual identification for the project, such as a picture of

the location where the system will be installed
SYSTEM: Provides important information about the Server where the
application is running and the product installed on the Server. This
information can be used for reference for technical support.

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LICENSE: In addition to the D-R HMI Studio license (Product License), the
application requires its own license, herein called Application License. The
Application license controls the maximum number of trains supported by
each one of the following modules: Control, Performance, Health, and
Rules.

1. License state: Indicates the current state of the license. The

possible states are:

- License not found. Please consult your software vendor: It

indicates that the Application License was not installed on the
computer where the application is running.
- Valid License: It indicates that the Application License is installed
and it supports the version of the application that is running.

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- Invalid License. Please consult your software vendor: It

indicates that the Application License was found on the computer
where the application is running, but it is invalid. The license can be
invalid for the following reasons:

The version of the application is higher than the version

assigned to the license

The network adapter used to generate the license is not

available in the local computer. It would happen either if the
application is copied to a different computer from the computer
where it was licensed, or if the network adapter used as
reference to generate the license was removed from the
computer.
2. Version: Version of the license (if any) installed on the computer
where the application is running.
3. Control: Maximum number of trains supported by the current
license (if any) for the Control Module.
4. Performance: Maximum number of trains supported by the current
license (if any) for the Performance Module.
5. Health: Maximum number of trains supported by the current license
(if any) for the Health Module.
6. Rules: Maximum number of trains supported by the current license
(if any) for the Rules Module.

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ABOUT: This interface provides an overview about Dresser-Rand and contact

information to the user.

Note: Please refer to D-R Controlled Manual ENVISION - INFORMATION -

Information Interface Operating Guide, M70-202-0805, which may be
found in Appendix A, following this section.

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CONFIGURATION MODULE
Configuration is the module that you use to configure all the modules and generic
settings for the DRCM Systems, from the TreeView, Screens and ContextBar up
to Performance Gases, Health Probes, and so forth.
Please note that not all tabs of this module are available unless the respective
module is enabled. For instance, if the project does not have Performance, the
tabs to configure the Performance module will not be presented.
Note: Please refer to D-R Controlled Manual ENVISION - CONFIGURATION -
Configuration Operating Guide, M70-301-0802, which may be found in
Appendix A, following this section.

CONTROL MODULE
Control Module is the module that you use as the Human-Machine Interface
(HMI) and Supervisory Control And Data Acquisition (SCADA) for the Dresser-
Rand Compressor.
This is the module that has the Process Mimics, PID Control Faceplates, Alarms
and Shutdowns Setpoint Configuration, Summary of Process Variables,
Permissives and Sequencing Screens and so forth.
Note: Please refer to D-R Controlled Manual DRCM - CONTROL - Control
Operating Guide, M70-200-0803, which may be found in Appendix A,
following this section.

E. DATA DISPLAY AND ICONS

The data and tag values can be displayed numerically and graphically. Several
standard icons and graphical data display standards are used to represent the
process and machinery status. Below are some examples of graphical display
icons and how they are used to illustrate the state of field equipment.
Valves with Solenoids. Standard color assignment is
Green = Open Yellow = Travel Red = Closed White = error
Solenoid color Green = Open Red = Closed

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Control Valve. Standard color assignment as above.

Pump. Standard color assignment is Red = Stopped Green = Run

Motors. Standard color assignment is Red = Stopped Green = Run

Status Switches. Green = good/clear/run state Red = bad/alert/alarm state

Cooler. Green = run/cool Red = stop/not cool

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Analog Value. Typically if the background color is green then the analog is within
all of its limits. If the background is white then the signal is in signal-fail. A small
circle F symbol will show up for analogs in signal fail also. If the background is a
Yellow color this indicates that the analog is in alarm, but this alarm is not a
shutdown alarm. There will be a yellow triangle with a black center to indicate
this state. Lastly there is a red colored background. This indicates that the
analog has caused a shutdown. There will also be an octagon symbol that is red
with an S in it.

Control Buttons. These buttons will send a command to the controller. If there is
feedback from the controller that the requested action has been accepted and is
being acted upon then the button will be highlighted with a yellow color.

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PID. The PID has several items to display. The three main tags are the Set
point (SP), the Process Variable (PV) and the Output signal to the controlled
device (Out). These three values are displayed both graphically and numerically.
They are shown as bar graphs and as numeric values. Since the SP and the PV
have the same units and the control is trying to match the PV with the SP value,
their bar graphs are shown next to each other. Since the Out may be reverse
acting or have different units and will not be at an analogous position when the
PV/SP stabilizes, it is in a different orientation. The generic PID faceplate has a
Local-Remote pair of buttons and a Auto-Manual pair of buttons. Depending
upon the control scheme and what is being controlled not all Remote-Local-Auto-
Manual combinations may be valid. If this is the case then some of the buttons
will be grayed out and will not perform any function. Some PIDs will have a
Remote Set Point (RSP) as well as a local SP. This is displayed on the
faceplate. Lastly there are the three PID factors: Proportional Gain (PG),
Integral Rate (IR) and Derivative Gain (DG). Depending upon the PID and the
users security level the PID faceplate will allow the user to select Local-Remote,
Auto-Manual. They can click on the SP and enter a new set point. They can
click on the output and enter a manual output. And lastly the operator can click
on the PID factors and enter a new set of factors. A typical faceplate is shown
below.

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F. DIALOGS AND DATA ENTRY

Most data entry in the HMI application involves multiple steps. Click on a point.
A window pops up where the user can enter new data. Then send the data to the
controller. For digital control (On-Off buttons, Start buttons, etc) a button is
pushed (clicked) then a pop-up window asks for confirmation before execution.
A few buttons like the PID Local-Remote provide action directly on the first click.
This section will review the pop-up dialog windows that are used for data entry or
action confirmation.
1. APPLICATION EXIT

Click on the icon in the Header section and the following window will
pop up. Click on Yes to stop the DR HMI or No to close the window with
no action

2. PRINTER SETUP

Click on the Printer setup icon in the header. This is the icon that
looks like a set of gears. It will pop up this window. The printer can be set
up for printing.

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3. ANALOG POINT LIMITS

Select an analog value and double Click on it. The following dialog box
will pop up. Alternately you can get this pop-up from the analog summary
sheet or the Analog limits summary. The alarm limits data base file
determines how many limits there will be for each analog, which limits will
apply and what they will be labeled. To enter a new limit, first select the
limit that you want to change. This will put the current value in the new
value slot at the bottom of the window. Then change the value in the new
value slot. Upon entering data in New value the send button will become
enabled. Click on Send and the dialog box will send the data and close.

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4. TIMER PRESET
Timer preset can be changed from the <<Timer Summary>> screen.
Select the timer on this screen whose preset needs to be changed. Select
edit timer. The following window will pop up. Select and enter new value.
Clicking on send will write the value to the controller, close this window
and refresh the timer summary display.

5. STATUS INFO
Right clicking on any status point on a screen will bring up the Status info
dialog screen. This could be a valve solenoid, a status indicator, a motor,
pump, etc. Alternately it can be brought up from the Status summary
screen. The dialog includes a lot of information about the status including
point numbers and addresses in the controller as well as a full description.
This dialog is not used to input any values. It is an information display only
screen.

This section will show

up only if there are two
status points associated
with this animation.

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6. ANALOG INFO
Right Clicking on any analog point will bring up the following dialog. The
dialog can also be brought up from the <<Analog Summary>> screen.
This dialog will include information about the analog point. It includes
point numbers and addresses in the controller as well as a full description.
This dialog is not used to input any values. It is an information display only
screen.

7. PID SET POINT WRITE

The dialog box shown below is used for inputing a new value to a PID.
This includes the Set Point, Manual Output, Proportional Gain, Integral
Rate, Derivative Gain values for the PID. This dialog is brought up by
clicking on the value to be input. If the PID is not in the correct mode to
accept one of the values then the dialog box will not come up. As an
example, if the PID is in Auto then it doesnt make sense to input a manual
output value so the dialog will not appear when you click on the output
value. Similarly if you are not signed on with high enough security, then
you cannot input new tuning parameters for the PID. In this case nothing
will happen when clicking on the tuning parameters.

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G. SCREENS
The screens for the following applications follow in Appendix B:

STEAM TURBINE COMPRESSOR UNIT CONTROL PANEL (UCP)

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