Compressor Station Control System Automation Upgrades
Springville, New York
The client’s compressor station consisted of five Cooper GMVH-10C2 compressor units (total station HP of 11,250). The client received approval to increase capacity to transport Pennsylvania-produced Marcellus Shale gas to the TransCanada Pipeline in western New York. The client required piping modifications and horsepower additions to allow the fuel gas to flow north.
The existing systems were a mixture of mature PLC control equipment and hardwired control schemes, and the facility was operated manually by operators. The design specs called for a fully-automatic system with remote monitoring and control. Existing hardware and end devices were unreliable, so new devices were required to allow for safe automatic control. New equipment and instrumentation were required for the piping modifications and capacity increase, which required electrical installation services. A solar turbine control system had to be integrated into the new station control system to allow for automatic control and monitoring from NFG Gas Control.
EN Engineering developed a controls design specification and electrical scope of work for implementation of the controls upgrade project, and provided engineering design, project management, drafting, programming, commissioning, and training services to guarantee stable and safe operation of the station, engine/compressors, and auxiliary equipment.
EN Engineering also supplied all of the necessary engineering, design, hardware, fabrication, software, and project management for five unit control panels, the station control panel, and three remote I/O panels. Complete drawing sets and documentation were provided to the client for factory acceptance testing of all panels and software prior to shipment for installation. In addition, EN Engineering provided engineering design services for the electrical installation of the controls upgrade project. Electrical equipment layout drawings, electrical details, schematics, and conduit and cable schedules were provided showing terminations and interconnection of new and existing I/O with the new control panels.
During the project, EN Engineering coordinated and managed the electrical installation and commissioning of the station and unit control systems. As part of the installation, individual systems were removed from service for a short duration, and upon completion, a commissioning team tested and calibrated the new equipment. An on-site acceptance test and startup was performed with the client prior to putting each station and unit control system into service. The entire project installation and cutover was successfully completed within the designated downtime allotment.