We have a Series 4 Compressor Control system (CCC). The system icludes AntiSurge Control, Performance, and Speed Control Applications. Each application has its own duplex IOM cards. The system is 6 years old and has been a maintenance nightmare since day one. The system is interfaced with the DCS via a Modbus Link. The troubles that we've faced already include the following :

1) Fatal failures of IOM cards which requires replacing them with another new expensive card. The manufacturer never provided a conviencing reasoning behind these Fatal Failures.

2) Vague System alarms that come up every once in a while causing the cards sometimes to switcover to its backups. These alarms are not even explained in the literature, or explained in a line or two that doesnt lead to anything. Apparently, it was meant to be that way to call for CCC service whenever it has a hiccup.

3) Meaningless Common alarms get sent to the DCS which sometimes causes the boardman to ignore real critical alarms.

4) Complicated sequencing of Steam Turbine Startups with alot of irrelvant steps and safeguards.

5) Very Poor seequence of events and history to be used for trip investigations.

6) The software Platform is full of bugs and not user-friendly.

Does anyone else have a similar experience, and what would be an efficent solution to replace this system?

Thank you all.

 

I have never worked with this particular controller but it sounds a lot like most proprietary controllers I have run across over the years. I am convinced that the primary reason OEMs sell them is to keep their service depts busy.

Bob Peterson

 

CCC are probably the best known and most knowlegable in the compression control industry, and I am quite surprised that you have having these problems.

1). Speak with CCC, its their design and they will know how to fix it.
2). Components keep failing. This sounds like you have had a less that satisfactory installation. I would check your earthing 7 or screening.
3). You need to do a alarm review, just like all facilities, make the alarms meaningful to the operators (panel man) this can easily be done on DCS level.
4). Get out the sequence table go through what is and is not required - then do a review with all displines and safety. Many sequences contain critical saftey checks that may seem "over the top" but are required for safe operating of the machine.
5). Your not doing sequence of events in the DCS? Use the systems for what they are truely designed for, DCS for control , visualisation, reporting etc and CCC for control of the compressor (turbine).
6). Remember your MODBUS link will not support time stamping so best to do your SOE in the DCS.
7). You will have to spend some money to get the system back up to acceptabale limits, if you equate the loss in downtime, trips and frustration will be way infront by getting out a CCC rep to help fix it and train you.

Hope this helps.
Shaun

 

I would suggest to you that in the future, should any of your process equipment like turbine/compressor expansion project, you should look into integrated turbine compressor control (ITCC) from turbo-machinery system vendors like Woodward, Petrotech and Triconex (Invensys). ITCC is very easy to maintain in terms of software and upgrading in the future unlike these single piece of controllers. Many users in Asia find these systems hard to maintain and understand.

Regards
Tan

 

Siemens has a S7 solution that I've heard lot of rave about, maybe you should look into it.

 

I design control systems and a lot of companies want CCC controllers and they do work if they are set up properly. Unfortunately the service man is not familiar with your application and this requires return trips. I used to stand there to be sure they were set up properly. You can program the surge algorythms into a PLC. Takes some time or you can use hardware controllers. Tricen 160, Woodward, and such. I prefer to program the algorythms into a PLC. The only drawback is the responce time. If the process requires a quick response (< 2 sec) the a hardware controller is the way to go. Most times the process can be set up to anticipate the problem and help to keep the machine out of surge. I try real hard not to use CCC controllers as you have to be a expert in smoke and mirrors to set them up. Find out who in you engineering group wrote the specification for the system and shoot them.

 

Bay Controls have a neat Control system that will do an excellent job chek them out. visit thir web site at http://www.baycontrols.com

 

Talk to Continuous Control Solutions, Inc. (http://www.ccsia.com) next time! They are also based in Des Moines, IA and they offer better technology on commonly known third party systems like Rockwell, Siemens, Honeywell, Yokogawa and so-on. You can actually diagnose it yourself and it has well known and market proven Modbus technology.

 

CCC has exceptionally good customer service. If CCC had a known manufacturer problem they would have told you and fixed it. However, in quite many cases the problems with controllers arise due to external factors (power interruptions, short circuits, ground loops) that need to be troubleshooted. If your personnel do not know how to troubleshoot around CCC equipment they may need to be trained. If you did ask CCC for help in the past and did not get your problems addressed it would be rather strange but you might have talked to the wrong person. If I were you I would contact CCC customer care and ask them for help.

Alex